Systems and methods for controlling a segmented circuit

ABSTRACT

The present disclosure provides a method for controlling a surgical instrument. The method includes connecting a power assembly to a control circuit, wherein the power assembly is configured to provide a source voltage, energizing, by the power assembly, a voltage boost convertor circuit configured to provide a set voltage greater than the source voltage, and energizing, by the voltage boost convertor, one or more voltage convertors configured to provide one or more operating voltages to one or more circuit components.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application claiming priority under35 U.S.C. § 120 to U.S. patent application Ser. No. 16/017,403, entitledSYSTEMS AND METHODS FOR CONTROLLING A SEGMENTED CIRCUIT, filed Jun. 25,2018, now U.S. Patent Application Publication No. 2019/0033955, which isa continuation application claiming priority under 35 U.S.C. § 120 toU.S. patent application Ser. No. 15/727,332, entitled SYSTEMS ANDMETHODS FOR CONTROLLING A SEGMENTED CIRCUIT, filed Oct. 6, 2017, whichissued on Nov. 6, 2018 as U.S. Pat. No. 10,117,653, which is acontinuation application claiming priority under 35 U.S.C. § 120 to U.S.patent application Ser. No. 14/226,081, entitled SYSTEMS AND METHODS FORCONTROLLING A SEGMENTED CIRCUIT, filed Mar. 26, 2014, which issued onOct. 31, 2017 as U.S. Pat. No. 9,804,618, the entire disclosures ofwhich are hereby incorporated by reference herein.

BACKGROUND

The present invention relates to surgical instruments and, in variouscircumstances, to surgical stapling and cutting instruments and staplecartridges therefor that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of this invention, and the manner ofattaining them, will become more apparent and the invention itself willbe better understood by reference to the following description ofinstances of the invention taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a perspective view of a surgical instrument comprising a powerassembly, a handle assembly, and an interchangeable shaft assembly;

FIG. 2 is perspective view of the surgical instrument of FIG. 1 with theinterchangeable shaft assembly separated from the handle assembly;

FIGS. 3A and 3B illustrate a circuit diagram of the surgical instrumentof FIG. 1;

FIGS. 4A and 4B illustrate one embodiment of a segmented circuitcomprising a plurality of circuit segments configured to control apowered surgical instrument;

FIGS. 5A and 5B illustrate a segmented circuit comprising a safetyprocessor configured to implement a watchdog function;

FIG. 6 illustrates a block diagram of one embodiment of a segmentedcircuit comprising a safety processor configured to monitor and comparea first property and a second property of a surgical instrument;

FIG. 7 illustrates a block diagram illustrating a safety processconfigured to be implemented by a safety processor;

FIG. 8 illustrates one embodiment of a four by four switch bankcomprising four input/output pins;

FIG. 9 illustrates one embodiment of a four by four bank circuitcomprising one input/output pin;

FIGS. 10A and 10B illustrate one embodiment of a segmented circuitcomprising a four by four switch bank coupled to a primary processor;

FIG. 11 illustrates one embodiment of a process for sequentiallyenergizing a segmented circuit;

FIG. 12 illustrates one embodiment of a power segment comprising aplurality of daisy chained power converters;

FIG. 13 illustrates one embodiment of a segmented circuit configured tomaximize power available for critical and/or power intense functions;

FIG. 14 illustrates one embodiment of a power system comprising aplurality of daisy chained power converters configured to besequentially energized;

FIG. 15 illustrates one embodiment of a segmented circuit comprising anisolated control section;

FIG. 16 illustrates one embodiment of a segmented circuit comprising anaccelerometer;

FIG. 17 illustrates one embodiment of a process for sequential start-upof a segmented circuit; and

FIG. 18 illustrates one embodiment of a method 1950 for controlling asurgical instrument comprising a segmented circuit, such as, forexample, the segmented control circuit 1602 illustrated in FIG. 12.

DETAILED DESCRIPTION

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 13/782,295, entitled ARTICULATABLESURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR SIGNAL COMMUNICATION,now U.S. Pat. No. 9,700,309;

U.S. patent application Ser. No. 13/782,323, entitled ROTARY POWEREDARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S. Pat. No.9,782,169;

U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL SWITCHARRANGEMENTS FOR SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2014/0249557;

U.S. patent application Ser. No. 13/782,499, entitled ELECTROMECHANICALSURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT, now U.S. Pat. No.9,358,003;

U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE PROCESSORMOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now U.S. Pat. No.9,554,794;

U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK SWITCHASSEMBLIES FOR SURGICAL INSTRUMENTS, now U.S. Pat. No. 9,326,767;

U.S. patent application Ser. No. 13/782,481, entitled SENSORSTRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR, now U.S. Pat.No. 9,468,438;

U.S. patent application Ser. No. 13/782,518, entitled CONTROL METHODSFOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS, now U.S.Patent Application Publication No. 2014/0246475;

U.S. patent application Ser. No. 13/782,375, entitled ROTARY POWEREDSURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM, now U.S. Pat. No.9,398,911; and

U.S. patent application Ser. No. 13/782,536, entitled SURGICALINSTRUMENT SOFT STOP, now U.S. Pat. No. 9,307,986 are herebyincorporated by reference in their entireties.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 13/803,097, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, now U.S. Pat. No.9,687,230;

U.S. patent application Ser. No. 13/803,193, entitled CONTROLARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, now U.S. Pat.No. 9,332,987;

U.S. patent application Ser. No. 13/803,053, entitled INTERCHANGEABLESHAFT ASSEMBLIES FOR USE WITH A SURGICAL INSTRUMENT, now U.S. Pat. No.9,883,860;

U.S. patent application Ser. No. 13/803,086, entitled ARTICULATABLESURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, now U.S. PatentApplication Publication No. 2014/0263541;

U.S. patent application Ser. No. 13/803,210, entitled SENSORARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL INSTRUMENTS,now U.S. Pat. No. 9,808,244;

U.S. patent application Ser. No. 13/803,148, entitled MULTI-FUNCTIONMOTOR FOR A SURGICAL INSTRUMENT, now U.S. Pat. No. 10,470,762;

U.S. patent application Ser. No. 13/803,066, entitled DRIVE SYSTEMLOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S. Pat. No.9,629,623;

U.S. patent application Ser. No. 13/803,117, entitled ARTICULATIONCONTROL SYSTEM FOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S. Pat. No.9,351,726;

U.S. patent application Ser. No. 13/803,130, entitled DRIVE TRAINCONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now U.S. Pat. No.9,351,727; and

U.S. patent application Ser. No. 13/803,159, entitled METHOD AND SYSTEMFOR OPERATING A SURGICAL INSTRUMENT, now U.S. Pat. No. 9,888,919.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 26, 2014 and are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 14/226,142, entitled SURGICALINSTRUMENT COMPRISING A SENSOR SYSTEM, now U.S. Pat. No. 9,913,642;

U.S. patent application Ser. No. 14/226,106, entitled POWER MANAGEMENTCONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Patent ApplicationPublication No. 2015/0272582;

U.S. patent application Ser. No. 14/226,099, entitled STERILIZATIONVERIFICATION CIRCUIT, now U.S. Pat. No. 9,826,977;

U.S. patent application Ser. No. 14/226,094, entitled VERIFICATION OFNUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT, now U.S. Patent ApplicationPublication No. 2015/0272580;

U.S. patent application Ser. No. 14/226,117, entitled POWER MANAGEMENTTHROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE UP CONTROL, now U.S.Pat. No. 10,013,049;

U.S. patent application Ser. No. 14/226,075, entitled MODULAR POWEREDSURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES, now U.S. Pat. No.9,743,929;

U.S. patent application Ser. No. 14/226,093, entitled FEEDBACKALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S.Pat. No. 10,028,761;

U.S. patent application Ser. No. 14/226,116, entitled SURGICALINSTRUMENT UTILIZING SENSOR ADAPTATION, now U.S. Patent ApplicationPublication No. 2015/0272571;

U.S. patent application Ser. No. 14/226,071, entitled SURGICALINSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR, now U.S. Pat. No.9,690,362;

U.S. patent application Ser. No. 14/226,097, entitled SURGICALINSTRUMENT COMPRISING INTERACTIVE SYSTEMS, now U.S. Pat. No. 9,820,738;

U.S. patent application Ser. No. 14/226,126, entitled INTERFACE SYSTEMSFOR USE WITH SURGICAL INSTRUMENTS, now U.S. Pat. No. 10,004,497;

U.S. patent application Ser. No. 14/226,133, entitled MODULAR SURGICALINSTRUMENT SYSTEM, now U.S. Patent Application Publication No.2015/0272557;

U.S. patent application Ser. No. 14/226,076, entitled POWER MANAGEMENTTHROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE PROTECTION, now U.S. Pat.No. 9,733,663;

U.S. patent application Ser. No. 14/226,111, entitled SURGICAL STAPLINGINSTRUMENT SYSTEM, now U.S. Pat. No. 9,750,499; and

U.S. patent application Ser. No. 14/226,125, entitled SURGICALINSTRUMENT COMPRISING A ROTATABLE SHAFT, now U.S. Pat. No. 10,201,364.

Certain exemplary embodiments will now be described to provide anoverall understanding of the principles of the structure, function,manufacture, and use of the devices and methods disclosed herein. One ormore examples of these embodiments are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that thedevices and methods specifically described herein and illustrated in theaccompanying drawings are non-limiting exemplary embodiments. Thefeatures illustrated or described in connection with one exemplaryembodiment may be combined with the features of other embodiments. Suchmodifications and variations are intended to be included within thescope of the present invention.

Reference throughout the specification to “various embodiments,” “someembodiments,” “one embodiment,” or “an embodiment”, or the like, meansthat a particular feature, structure, or characteristic described inconnection with the embodiment is included in at least one embodiment.Thus, appearances of the phrases “in various embodiments,” “in someembodiments,” “in one embodiment”, or “in an embodiment”, or the like,in places throughout the specification are not necessarily all referringto the same embodiment. Furthermore, the particular features,structures, or characteristics may be combined in any suitable manner inone or more embodiments. Thus, the particular features, structures, orcharacteristics illustrated or described in connection with oneembodiment may be combined, in whole or in part, with the featuresstructures, or characteristics of one or more other embodiments withoutlimitation. Such modifications and variations are intended to beincluded within the scope of the present invention.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” referring to the portion closest to the clinicianand the term “distal” referring to the portion located away from theclinician. It will be further appreciated that, for convenience andclarity, spatial terms such as “vertical,” “horizontal,” “up,” and“down” may be used herein with respect to the drawings. However,surgical instruments are used in many orientations and positions, andthese terms are not intended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, theperson of ordinary skill in the art will readily appreciate that thevarious methods and devices disclosed herein can be used in numeroussurgical procedures and applications including, for example, inconnection with open surgical procedures. As the present DetailedDescription proceeds, those of ordinary skill in the art will furtherappreciate that the various instruments disclosed herein can be insertedinto a body in any way, such as through a natural orifice, through anincision or puncture hole formed in tissue, etc. The working portions orend effector portions of the instruments can be inserted directly into apatient's body or can be inserted through an access device that has aworking channel through which the end effector and elongated shaft of asurgical instrument can be advanced.

FIGS. 1-3B generally depict a motor-driven surgical fastening andcutting instrument 2000. As illustrated in FIGS. 1 and 2, the surgicalinstrument 2000 may include a handle assembly 2002, a shaft assembly2004, and a power assembly 2006 (“power source,” “power pack,” or“battery pack”). The shaft assembly 2004 may include an end effector2008 which, in certain circumstances, can be configured to act as anendocutter for clamping, severing, and/or stapling tissue, although, inother embodiments, different types of end effectors may be used, such asend effectors for other types of surgical devices, graspers, cutters,staplers, clip appliers, access devices, drug/gene therapy devices,ultrasound devices, RF device, and/or laser devices, for example.Several RF devices may be found in U.S. Pat. No. 5,403,312, entitledELECTROSURGICAL HEMOSTATIC DEVICE, which issued on Apr. 4, 1995, andU.S. patent application Ser. No. 12/031,573, entitled SURGICAL FASTENINGAND CUTTING INSTRUMENT HAVING RF ELECTRODES, filed Feb. 14, 2008, theentire disclosures of which are incorporated herein by reference intheir entirety.

Referring primarily to FIGS. 2, 3A and 3B, the handle assembly 2002 canbe employed with a plurality of interchangeable shaft assemblies suchas, for example, the shaft assembly 2004. Such interchangeable shaftassemblies may comprise surgical end effectors such as, for example, theend effector 2008 that can be configured to perform one or more surgicaltasks or procedures. Examples of suitable interchangeable shaftassemblies are disclosed in U.S. Provisional Patent Application Ser. No.61/782,866, entitled CONTROL SYSTEM OF A SURGICAL INSTRUMENT, and filedMar. 14, 2013, the entire disclosure of which is hereby incorporated byreference herein in its entirety.

Referring primarily to FIG. 2, the handle assembly 2002 may comprise ahousing 2010 that consists of a handle 2012 that may be configured to begrasped, manipulated and actuated by a clinician. However, it will beunderstood that the various unique and novel arrangements of the variousforms of interchangeable shaft assemblies disclosed herein may also beeffectively employed in connection with robotically-controlled surgicalsystems. Thus, the term “housing” may also encompass a housing orsimilar portion of a robotic system that houses or otherwise operablysupports at least one drive system that is configured to generate andapply at least one control motion which could be used to actuate theinterchangeable shaft assemblies disclosed herein and their respectiveequivalents. For example, the interchangeable shaft assemblies disclosedherein may be employed with various robotic systems, instruments,components and methods disclosed in U.S. patent application Ser. No.13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535, which isincorporated by reference herein in its entirety.

Referring again to FIG. 2, the handle assembly 2002 may operably supporta plurality of drive systems therein that can be configured to generateand apply various control motions to corresponding portions of theinterchangeable shaft assembly that is operably attached thereto. Forexample, the handle assembly 2002 can operably support a first orclosure drive system, which may be employed to apply closing and openingmotions to the shaft assembly 2004 while operably attached or coupled tothe handle assembly 2002. In at least one form, the handle assembly 2002may operably support a firing drive system that can be configured toapply firing motions to corresponding portions of the interchangeableshaft assembly attached thereto.

Referring primarily to FIGS. 3A and 3B, the handle assembly 2002 mayinclude a motor 2014 which can be controlled by a motor driver 2015 andcan be employed by the firing system of the surgical instrument 2000. Invarious forms, the motor 2014 may be a DC brushed driving motor having amaximum rotation of, approximately, 25,000 RPM, for example. In otherarrangements, the motor 2014 may include a brushless motor, a cordlessmotor, a synchronous motor, a stepper motor, or any other suitableelectric motor. In certain circumstances, the motor driver 2015 maycomprise an H-Bridge field-effect transistors (FETs) 2019, asillustrated in FIGS. 3A and 3B, for example. The motor 2014 can bepowered by the power assembly 2006 (FIGS. 3A and 3B) which can bereleasably mounted to the handle assembly 2002 for supplying controlpower to the surgical instrument 2000. The power assembly 2006 maycomprise a battery which may include a number of battery cells connectedin series that can be used as the power source to power the surgicalinstrument 2000. In certain circumstances, the battery cells of thepower assembly 2006 may be replaceable and/or rechargeable. In at leastone example, the battery cells can be Lithium-Ion batteries which can beseparably couplable to the power assembly 2006.

The shaft assembly 2004 may include a shaft assembly controller 2022which can communicate with the power management controller 2016 throughan interface while the shaft assembly 2004 and the power assembly 2006are coupled to the handle assembly 2002. For example, the interface maycomprise a first interface portion 2025 which may include one or moreelectric connectors for coupling engagement with corresponding shaftassembly electric connectors and a second interface portion 2027 whichmay include one or more electric connectors for coupling engagement withcorresponding power assembly electric connectors to permit electricalcommunication between the shaft assembly controller 2022 and the powermanagement controller 2016 while the shaft assembly 2004 and the powerassembly 2006 are coupled to the handle assembly 2002. One or morecommunication signals can be transmitted through the interface tocommunicate one or more of the power requirements of the attachedinterchangeable shaft assembly 2004 to the power management controller2016. In response, the power management controller may modulate thepower output of the battery of the power assembly 2006, as describedbelow in greater detail, in accordance with the power requirements ofthe attached shaft assembly 2004. In certain circumstances, one or moreof the electric connectors may comprise switches which can be activatedafter mechanical coupling engagement of the handle assembly 2002 to theshaft assembly 2004 and/or to the power assembly 2006 to allowelectrical communication between the shaft assembly controller 2022 andthe power management controller 2016.

In certain circumstances, the interface can facilitate transmission ofthe one or more communication signals between the power managementcontroller 2016 and the shaft assembly controller 2022 by routing suchcommunication signals through a main controller 2017 residing in thehandle assembly 2002, for example. In other circumstances, the interfacecan facilitate a direct line of communication between the powermanagement controller 2016 and the shaft assembly controller 2022through the handle assembly 2002 while the shaft assembly 2004 and thepower assembly 2006 are coupled to the handle assembly 2002.

In one instance, the main microcontroller 2017 may be any single core ormulticore processor such as those known under the trade name ARM Cortexby Texas Instruments. In one instance, the surgical instrument 2000 maycomprise a power management controller 2016 such as, for example, asafety microcontroller platform comprising two microcontroller-basedfamilies such as TMS570 and RM4x known under the trade name Hercules ARMCortex R4, also by Texas Instruments. Nevertheless, other suitablesubstitutes for microcontrollers and safety processor may be employed,without limitation. In one instance, the safety processor may beconfigured specifically for IEC 61508 and ISO 26262 safety criticalapplications, among others, to provide advanced integrated safetyfeatures while delivering scalable performance, connectivity, and memoryoptions.

In certain instances, the microcontroller 2017 may be an LM4F230H5QR,available from Texas Instruments, for example. In at least one example,the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Corecomprising on-chip memory of 256 KB single-cycle flash memory, or othernon-volatile memory, up to 40 MHz, a prefetch buffer to improveperformance above 40 MHz, a 32 KB single-cycle serial random accessmemory (SRAM), internal read-only memory (ROM) loaded withStellarisWare® software, 2 KB electrically erasable programmableread-only memory (EEPROM), one or more pulse width modulation (PWM)modules, one or more quadrature encoder inputs (QEI) analog, one or more12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels,among other features that are readily available for the productdatasheet. The present disclosure should not be limited in this context.

The power assembly 2006 may include a power management circuit which maycomprise the power management controller 2016, a power modulator 2038,and a current sense circuit 2036. The power management circuit can beconfigured to modulate power output of the battery based on the powerrequirements of the shaft assembly 2004 while the shaft assembly 2004and the power assembly 2006 are coupled to the handle assembly 2002. Forexample, the power management controller 2016 can be programmed tocontrol the power modulator 2038 of the power output of the powerassembly 2006 and the current sense circuit 2036 can be employed tomonitor power output of the power assembly 2006 to provide feedback tothe power management controller 2016 about the power output of thebattery so that the power management controller 2016 may adjust thepower output of the power assembly 2006 to maintain a desired output.

It is noteworthy that the power management controller 2016 and/or theshaft assembly controller 2022 each may comprise one or more processorsand/or memory units which may store a number of software modules.Although certain modules and/or blocks of the surgical instrument 2000may be described by way of example, it can be appreciated that a greateror lesser number of modules and/or blocks may be used. Further, althoughvarious instances may be described in terms of modules and/or blocks tofacilitate description, such modules and/or blocks may be implemented byone or more hardware components, e.g., processors, Digital SignalProcessors (DSPs), Programmable Logic Devices (PLDs), ApplicationSpecific Integrated Circuits (ASICs), circuits, registers and/orsoftware components, e.g., programs, subroutines, logic and/orcombinations of hardware and software components.

In certain instances, the surgical instrument 2000 may comprise anoutput device 2042 which may include one or more devices for providing asensory feedback to a user. Such devices may comprise, for example,visual feedback devices (e.g., an LCD display screen, LED indicators),audio feedback devices (e.g., a speaker, a buzzer) or tactile feedbackdevices (e.g., haptic actuators). In certain circumstances, the outputdevice 2042 may comprise a display 2043 which may be included in thehandle assembly 2002. The shaft assembly controller 2022 and/or thepower management controller 2016 can provide feedback to a user of thesurgical instrument 2000 through the output device 2042. The interface2024 can be configured to connect the shaft assembly controller 2022and/or the power management controller 2016 to the output device 2042.The reader will appreciate that the output device 2042 can instead beintegrated with the power assembly 2006. In such circumstances,communication between the output device 2042 and the shaft assemblycontroller 2022 may be accomplished through the interface 2024 while theshaft assembly 2004 is coupled to the handle assembly 2002.

Having described a surgical instrument 2000 in general terms, thedescription now turns to a detailed description of variouselectrical/electronic component of the surgical instrument 2000. Forexpedience, any references hereinbelow to the surgical instrument 2000should be construed to refer to the surgical instrument 2000 shown inconnection with FIGS. 1-3B. Turning now to FIGS. 4A and 4B, where oneembodiment of a segmented circuit 1000 comprising a plurality of circuitsegments 1002 a-1002 g is illustrated. The segmented circuit 1000comprising the plurality of circuit segments 1002 a-1002 g is configuredto control a powered surgical instrument, such as, for example, thesurgical instrument 2000 illustrated in FIGS. 1-3B, without limitation.The plurality of circuit segments 1002 a-1002 g is configured to controlone or more operations of the powered surgical instrument 2000. A safetyprocessor segment 1002 a (Segment 1) comprises a safety processor 1004.A primary processor segment 1002 b (Segment 2) comprises a primaryprocessor 1006. The safety processor 1004 and/or the primary processor1006 are configured to interact with one or more additional circuitsegments 1002 c-1002 g to control operation of the powered surgicalinstrument 2000. The primary processor 1006 comprises a plurality ofinputs coupled to, for example, one or more circuit segments 1002 c-1002g, a battery 1008, and/or a plurality of switches 1058 a-1070. Thesegmented circuit 1000 may be implemented by any suitable circuit, suchas, for example, a printed circuit board assembly (PCBA) within thepowered surgical instrument 2000. It should be understood that the termprocessor as used herein includes any microprocessor, microcontroller,or other basic computing device that incorporates the functions of acomputer's central processing unit (CPU) on an integrated circuit or atmost a few integrated circuits. The processor is a multipurpose,programmable device that accepts digital data as input, processes itaccording to instructions stored in its memory, and provides results asoutput. It is an example of sequential digital logic, as it has internalmemory. Processors operate on numbers and symbols represented in thebinary numeral system.

In one embodiment, the main processor 1006 may be any single core ormulticore processor such as those known under the trade name ARM Cortexby Texas Instruments. In one embodiment, the safety processor 1004 maybe a safety microcontroller platform comprising twomicrocontroller-based families such as TMS570 and RM4x known under thetrade name Hercules ARM Cortex R4, also by Texas Instruments.Nevertheless, other suitable substitutes for microcontrollers and safetyprocessor may be employed, without limitation. In one embodiment, thesafety processor 1004 may be configured specifically for IEC 61508 andISO 26262 safety critical applications, among others, to provideadvanced integrated safety features while delivering scalableperformance, connectivity, and memory options.

In certain instances, the main processor 1006 may be an LM4F230H5QR,available from Texas Instruments, for example. In at least one example,the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F Processor Corecomprising on-chip memory of 256 KB single-cycle flash memory, or othernon-volatile memory, up to 40 MHz, a prefetch buffer to improveperformance above 40 MHz, a 32 KB single-cycle serial random accessmemory (SRAM), internal read-only memory (ROM) loaded withStellarisWare® software, 2 KB electrically erasable programmableread-only memory (EEPROM), one or more pulse width modulation (PWM)modules, one or more quadrature encoder inputs (QEI) analog, one or more12-bit Analog-to-Digital Converters (ADC) with 12 analog input channels,among other features that are readily available for the productdatasheet. Other processors may be readily substituted and, accordingly,the present disclosure should not be limited in this context.

In one embodiment, the segmented circuit 1000 comprises an accelerationsegment 1002 c (Segment 3). The acceleration segment 1002 c comprises anacceleration sensor 1022. The acceleration sensor 1022 may comprise, forexample, an accelerometer. The acceleration sensor 1022 is configured todetect movement or acceleration of the powered surgical instrument 2000.In some embodiments, input from the acceleration sensor 1022 is used,for example, to transition to and from a sleep mode, identify anorientation of the powered surgical instrument, and/or identify when thesurgical instrument has been dropped. In some embodiments, theacceleration segment 1002 c is coupled to the safety processor 1004and/or the primary processor 1006.

In one embodiment, the segmented circuit 1000 comprises a displaysegment 1002 d (Segment 4). The display segment 1002 d comprises adisplay connector 1024 coupled to the primary processor 1006. Thedisplay connector 1024 couples the primary processor 1006 to a display1028 through one or more display driver integrated circuits 1026. Thedisplay driver integrated circuits 1026 may be integrated with thedisplay 1028 and/or may be located separately from the display 1028. Thedisplay 1028 may comprise any suitable display, such as, for example, anorganic light-emitting diode (OLED) display, a liquid-crystal display(LCD), and/or any other suitable display. In some embodiments, thedisplay segment 1002 d is coupled to the safety processor 1004.

In some embodiments, the segmented circuit 1000 comprises a shaftsegment 1002 e (Segment 5). The shaft segment 1002 e comprises one ormore controls for a shaft 2004 coupled to the surgical instrument 2000and/or one or more controls for an end effector 2006 coupled to theshaft 2004. The shaft segment 1002 e comprises a shaft connector 1030configured to couple the primary processor 1006 to a shaft PCBA 1031.The shaft PCBA 1031 comprises a first articulation switch 1036, a secondarticulation switch 1032, and a shaft PCBA electrically erasableprogrammable read-only memory (EEPROM) 1034. In some embodiments, theshaft PCBA EEPROM 1034 comprises one or more parameters, routines,and/or programs specific to the shaft 2004 and/or the shaft PCBA 1031.The shaft PCBA 1031 may be coupled to the shaft 2004 and/or integralwith the surgical instrument 2000. In some embodiments, the shaftsegment 1002 e comprises a second shaft EEPROM 1038. The second shaftEEPROM 1038 comprises a plurality of algorithms, routines, parameters,and/or other data corresponding to one or more shafts 2004 and/or endeffectors 2006 which may be interfaced with the powered surgicalinstrument 2000.

In some embodiments, the segmented circuit 1000 comprises a positionencoder segment 1002 f (Segment 6). The position encoder segment 1002 fcomprises one or more magnetic rotary position encoders 1040 a-1040 b.The one or more magnetic rotary position encoders 1040 a-1040 b areconfigured to identify the rotational position of a motor 1048, a shaft2004, and/or an end effector 2006 of the surgical instrument 2000. Insome embodiments, the magnetic rotary position encoders 1040 a-1040 bmay be coupled to the safety processor 1004 and/or the primary processor1006.

In some embodiments, the segmented circuit 1000 comprises a motorsegment 1002 g (Segment 7). The motor segment 1002 g comprises a motor1048 configured to control one or more movements of the powered surgicalinstrument 2000. The motor 1048 is coupled to the primary processor 1006by an H-Bridge driver 1042 and one or more H-bridge field-effecttransistors (FETs) 1044. The H-bridge FETs 1044 are coupled to thesafety processor 1004. A motor current sensor 1046 is coupled in serieswith the motor 1048 to measure the current draw of the motor 1048. Themotor current sensor 1046 is in signal communication with the primaryprocessor 1006 and/or the safety processor 1004. In some embodiments,the motor 1048 is coupled to a motor electromagnetic interference (EMI)filter 1050.

The segmented circuit 1000 comprises a power segment 1002 h (Segment 8).A battery 1008 is coupled to the safety processor 1004, the primaryprocessor 1006, and one or more of the additional circuit segments 1002c-1002 g. The battery 1008 is coupled to the segmented circuit 1000 by abattery connector 1010 and a current sensor 1012. The current sensor1012 is configured to measure the total current draw of the segmentedcircuit 1000. In some embodiments, one or more voltage converters 1014a, 1014 b, 1016 are configured to provide predetermined voltage valuesto one or more circuit segments 1002 a-1002 g. For example, in someembodiments, the segmented circuit 1000 may comprise 3.3V voltageconverters 1014 a-1014 b and/or 5V voltage converters 1016. A boostconverter 1018 is configured to provide a boost voltage up to apredetermined amount, such as, for example, up to 13V. The boostconverter 1018 is configured to provide additional voltage and/orcurrent during power intensive operations and prevent brownout orlow-power conditions.

In some embodiments, the safety segment 1002 a comprises a motor powerinterrupt 1020. The motor power interrupt 1020 is coupled between thepower segment 1002 h and the motor segment 1002 g. The safety segment1002 a is configured to interrupt power to the motor segment 1002 g whenan error or fault condition is detected by the safety processor 1004and/or the primary processor 1006 as discussed in more detail herein.Although the circuit segments 1002 a-1002 g are illustrated with allcomponents of the circuit segments 1002 a-1002 h located in physicalproximity, one skilled in the art will recognize that a circuit segment1002 a-1002 h may comprise components physically and/or electricallyseparate from other components of the same circuit segment 1002 a-1002g. In some embodiments, one or more components may be shared between twoor more circuit segments 1002 a-1002 g.

In some embodiments, a plurality of switches 1056-1070 are coupled tothe safety processor 1004 and/or the primary processor 1006. Theplurality of switches 1056-1070 may be configured to control one or moreoperations of the surgical instrument 2000, control one or moreoperations of the segmented circuit 1100, and/or indicate a status ofthe surgical instrument 2000. For example, a bail-out door switch 1056is configured to indicate the status of a bail-out door. A plurality ofarticulation switches, such as, for example, a left side articulationleft switch 1058 a, a left side articulation right switch 1060 a, a leftside articulation center switch 1062 a, a right side articulation leftswitch 1058 b, a right side articulation right switch 1060 b, and aright side articulation center switch 1062 b are configured to controlarticulation of a shaft 2004 and/or an end effector 2006. A left sidereverse switch 1064 a and a right side reverse switch 1064 b are coupledto the primary processor 1006. In some embodiments, the left sideswitches comprising the left side articulation left switch 1058 a, theleft side articulation right switch 1060 a, the left side articulationcenter switch 1062 a, and the left side reverse switch 1064 a arecoupled to the primary processor 1006 by a left flex connector 1072 a.The right side switches comprising the right side articulation leftswitch 1058 b, the right side articulation right switch 1060 b, theright side articulation center switch 1062 b, and the right side reverseswitch 1064 b are coupled to the primary processor 1006 by a right flexconnector 1072 b. In some embodiments, a firing switch 1066, a clamprelease switch 1068, and a shaft engaged switch 1070 are coupled to theprimary processor 1006.

The plurality of switches 1056-1070 may comprise, for example, aplurality of handle controls mounted to a handle of the surgicalinstrument 2000, a plurality of indicator switches, and/or anycombination thereof. In various embodiments, the plurality of switches1056-1070 allow a surgeon to manipulate the surgical instrument, providefeedback to the segmented circuit 1000 regarding the position and/oroperation of the surgical instrument, and/or indicate unsafe operationof the surgical instrument 2000. In some embodiments, additional orfewer switches may be coupled to the segmented circuit 1000, one or moreof the switches 1056-1070 may be combined into a single switch, and/orexpanded to multiple switches. For example, in one embodiment, one ormore of the left side and/or right side articulation switches 1058a-1064 b may be combined into a single multi-position switch.

FIGS. 5A and 5B illustrate a segmented circuit 1100 comprising oneembodiment of a safety processor 1104 configured to implement a watchdogfunction, among other safety operations. The safety processor 1004 andthe primary processor 1106 of the segmented circuit 1100 are in signalcommunication. A plurality of circuit segments 1102 c-1102 h are coupledto the primary processor 1106 and are configured to control one or moreoperations of a surgical instrument, such as, for example, the surgicalinstrument 2000 illustrated in FIGS. 1-3B. For example, in theillustrated embodiment, the segmented circuit 1100 comprises anacceleration segment 1102 c, a display segment 1102 d, a shaft segment1102 e, an encoder segment 1102 f, a motor segment 1102 g, and a powersegment 1102 h. Each of the circuit segments 1102 c-1102 g may becoupled to the safety processor 1104 and/or the primary processor 1106.The primary processor is also coupled to a flash memory 1186. Amicroprocessor alive heartbeat signal is provided at output 1196.

The acceleration segment 1102 c comprises an accelerometer 1122configured to monitor movement of the surgical instrument 2000. Invarious embodiments, the accelerometer 1122 may be a single, double, ortriple axis accelerometer. The accelerometer 1122 may be employed tomeasures proper acceleration that is not necessarily the coordinateacceleration (rate of change of velocity). Instead, the accelerometersees the acceleration associated with the phenomenon of weightexperienced by a test mass at rest in the frame of reference of theaccelerometer 1122. For example, the accelerometer 1122 at rest on thesurface of the earth will measure an acceleration g=9.8 m/s² (gravity)straight upwards, due to its weight. Another type of acceleration thataccelerometer 1122 can measure is g-force acceleration. In various otherembodiments, the accelerometer 1122 may comprise a single, double, ortriple axis accelerometer. Further, the acceleration segment 1102 c maycomprise one or more inertial sensors to detect and measureacceleration, tilt, shock, vibration, rotation, and multipledegrees-of-freedom (DoF). A suitable inertial sensor may comprise anaccelerometer (single, double, or triple axis), a magnetometer tomeasure a magnetic field in space such as the earth's magnetic field,and/or a gyroscope to measure angular velocity.

The display segment 1102 d comprises a display embedded in the surgicalinstrument 2000, such as, for example, an OLED display. In certainembodiments, the surgical instrument 2000 may comprise an output devicewhich may include one or more devices for providing a sensory feedbackto a user. Such devices may comprise, for example, visual feedbackdevices (e.g., an LCD display screen, LED indicators), audio feedbackdevices (e.g., a speaker, a buzzer) or tactile feedback devices (e.g.,haptic actuators). In some aspects, the output device may comprise adisplay which may be included in the handle assembly 2002, asillustrated in FIG. 1. The shaft assembly controller and/or the powermanagement controller can provide feedback to a user of the surgicalinstrument 2000 through the output device. An interface can beconfigured to connect the shaft assembly controller and/or the powermanagement controller to the output device.

The shaft segment 1102 e comprises a shaft circuit board 1131, such as,for example, a shaft PCB, configured to control one or more operationsof a shaft 2004 and/or an end effector 2006 coupled to the shaft 2004and a Hall effect switch 1170 to indicate shaft engagement. The shaftcircuit board 1131 also includes a low-power microprocessor 1190 withferroelectric random access memory (FRAM) technology, a mechanicalarticulation switch 1192, a shaft release Hall Effect switch 1194, andflash memory 1134. The encoder segment 1102 f comprises a plurality ofmotor encoders 1140 a, 1140 b configured to provide rotational positioninformation of a motor 1048, the shaft 2004, and/or the end effector2006.

The motor segment 1102 g comprises a motor 1048, such as, for example, abrushed DC motor. The motor 1048 is coupled to the primary processor1106 through a plurality of H-bridge drivers 1142 and a motor controller1143. The motor controller 1143 controls a first motor flag 1174 a and asecond motor flag 1174 b to indicate the status and position of themotor 1048 to the primary processor 1106. The primary processor 1106provides a pulse-width modulation (PWM) high signal 1176 a, a PWM lowsignal 1176 b, a direction signal 1178, a synchronize signal 1180, and amotor reset signal 1182 to the motor controller 1143 through a buffer1184. The power segment 1102 h is configured to provide a segmentvoltage to each of the circuit segments 1102 a-1102 g.

In one embodiment, the safety processor 1104 is configured to implementa watchdog function with respect to one or more circuit segments 1102c-1102 h, such as, for example, the motor segment 1102 g. In thisregards, the safety processor 1104 employs the watchdog function todetect and recover from malfunctions of the primary processor 10006.During normal operation, the safety processor 1104 monitors for hardwarefaults or program errors of the primary processor 1104 and to initiatecorrective action or actions. The corrective actions may include placingthe primary processor 10006 in a safe state and restoring normal systemoperation. In one embodiment, the safety processor 1104 is coupled to atleast a first sensor. The first sensor measures a first property of thesurgical instrument 2000. In some embodiments, the safety processor 1104is configured to compare the measured property of the surgicalinstrument 2000 to a predetermined value. For example, in oneembodiment, a motor sensor 1140 a is coupled to the safety processor1104. The motor sensor 1140 a provides motor speed and positioninformation to the safety processor 1104. The safety processor 1104monitors the motor sensor 1140 a and compares the value to a maximumspeed and/or position value and prevents operation of the motor 1048above the predetermined values. In some embodiments, the predeterminedvalues are calculated based on real-time speed and/or position of themotor 1048, calculated from values supplied by a second motor sensor1140 b in communication with the primary processor 1106, and/or providedto the safety processor 1104 from, for example, a memory module coupledto the safety processor 1104.

In some embodiments, a second sensor is coupled to the primary processor1106. The second sensor is configured to measure the first physicalproperty. The safety processor 1104 and the primary processor 1106 areconfigured to provide a signal indicative of the value of the firstsensor and the second sensor respectively. When either the safetyprocessor 1104 or the primary processor 1106 indicates a value outsideof an acceptable range, the segmented circuit 1100 prevents operation ofat least one of the circuit segments 1102 c-1102 h, such as, forexample, the motor segment 1102 g. For example, in the embodimentillustrated in FIGS. 5A and 5B, the safety processor 1104 is coupled toa first motor position sensor 1140 a and the primary processor 1106 iscoupled to a second motor position sensor 1140 b. The motor positionsensors 1140 a, 1140 b may comprise any suitable motor position sensor,such as, for example, a magnetic angle rotary input comprising a sineand cosine output. The motor position sensors 1140 a, 1140 b providerespective signals to the safety processor 1104 and the primaryprocessor 1106 indicative of the position of the motor 1048.

The safety processor 1104 and the primary processor 1106 generate anactivation signal when the values of the first motor sensor 1140 a andthe second motor sensor 1140 b are within a predetermined range. Wheneither the primary processor 1106 or the safety processor 1104 to detecta value outside of the predetermined range, the activation signal isterminated and operation of at least one circuit segment 1102 c-1102 h,such as, for example, the motor segment 1102 g, is interrupted and/orprevented. For example, in some embodiments, the activation signal fromthe primary processor 1106 and the activation signal from the safetyprocessor 1104 are coupled to an AND gate. The AND gate is coupled to amotor power switch 1120. The AND gate maintains the motor power switch1120 in a closed, or on, position when the activation signal from boththe safety processor 1104 and the primary processor 1106 are high,indicating a value of the motor sensors 1140 a, 1140 b within thepredetermined range. When either of the motor sensors 1140 a, 1140 bdetect a value outside of the predetermined range, the activation signalfrom that motor sensor 1140 a, 1140 b is set low, and the output of theAND gate is set low, opening the motor power switch 1120. In someembodiments, the value of the first sensor 1140 a and the second sensor1140 b is compared, for example, by the safety processor 1104 and/or theprimary processor 1106. When the values of the first sensor and thesecond sensor are different, the safety processor 1104 and/or theprimary processor 1106 may prevent operation of the motor segment 1102g.

In some embodiments, the safety processor 1104 receives a signalindicative of the value of the second sensor 1140 b and compares thesecond sensor value to the first sensor value. For example, in oneembodiment, the safety processor 1104 is coupled directly to a firstmotor sensor 1140 a. A second motor sensor 1140 b is coupled to aprimary processor 1106, which provides the second motor sensor 1140 bvalue to the safety processor 1104, and/or coupled directly to thesafety processor 1104. The safety processor 1104 compares the value ofthe first motor sensor 1140 to the value of the second motor sensor 1140b. When the safety processor 1104 detects a mismatch between the firstmotor sensor 1140 a and the second motor sensor 1140 b, the safetyprocessor 1104 may interrupt operation of the motor segment 1102 g, forexample, by cutting power to the motor segment 1102 g.

In some embodiments, the safety processor 1104 and/or the primaryprocessor 1106 is coupled to a first sensor 1140 a configured to measurea first property of a surgical instrument and a second sensor 1140 bconfigured to measure a second property of the surgical instrument. Thefirst property and the second property comprise a predeterminedrelationship when the surgical instrument is operating normally. Thesafety processor 1104 monitors the first property and the secondproperty. When a value of the first property and/or the second propertyinconsistent with the predetermined relationship is detected, a faultoccurs. When a fault occurs, the safety processor 1104 takes at leastone action, such as, for example, preventing operation of at least oneof the circuit segments, executing a predetermined operation, and/orresetting the primary processor 1106. For example, the safety processor1104 may open the motor power switch 1120 to cut power to the motorcircuit segment 1102 g when a fault is detected.

FIG. 6 illustrates a block diagram of one embodiment of a segmentedcircuit 1200 comprising a safety processor 1204 configured to monitorand compare a first property and a second property of a surgicalinstrument, such as, for example, the surgical instrument 2000illustrated in FIGS. 1-3B. The safety processor 1204 is coupled to afirst sensor 1246 and a second sensor 1266. The first sensor 1246 isconfigured to monitor a first physical property of the surgicalinstrument 2000. The second sensor 1266 is configured to monitor asecond physical property of the surgical instrument 2000. The first andsecond properties comprise a predetermined relationship when thesurgical instrument 2000 is operating normally. For example, in oneembodiment, the first sensor 1246 comprises a motor current sensorconfigured to monitor the current draw of a motor from a power source.The motor current draw may be indicative of the speed of the motor. Thesecond sensor comprises a linear hall sensor configured to monitor theposition of a cutting member within an end effector, for example, an endeffector 2006 coupled to the surgical instrument 2000. The position ofthe cutting member is used to calculate a cutting member speed withinthe end effector 2006. The cutting member speed has a predeterminedrelationship with the speed of the motor when the surgical instrument2000 is operating normally.

The safety processor 1204 provides a signal to the main processor 1206indicating that the first sensor 1246 and the second sensor 1266 areproducing values consistent with the predetermined relationship. Whenthe safety processor 1204 detects a value of the first sensor 1246and/or the second sensor 1266 inconsistent with the predeterminedrelationship, the safety processor 1206 indicates an unsafe condition tothe primary processor 1206. The primary processor 1206 interrupts and/orprevents operation of at least one circuit segment. In some embodiments,the safety processor 1204 is coupled directly to a switch configured tocontrol operation of one or more circuit segments. For example, withreference to FIGS. 5A and 5B, in one embodiment, the safety processor1104 is coupled directly to a motor power switch 1120. The safetyprocessor 1104 opens the motor power switch 1120 to prevent operation ofthe motor segment 1102 g when a fault is detected.

Referring back to FIGS. 5A and 5B, in one embodiment, the safetyprocessor 1104 is configured to execute an independent controlalgorithm. In operation, the safety processor 1104 monitors thesegmented circuit 1100 and is configured to control and/or overridesignals from other circuit components, such as, for example, the primaryprocessor 1106, independently. The safety processor 1104 may execute apreprogrammed algorithm and/or may be updated or programmed on the flyduring operation based on one or more actions and/or positions of thesurgical instrument 2000. For example, in one embodiment, the safetyprocessor 1104 is reprogrammed with new parameters and/or safetyalgorithms each time a new shaft and/or end effector is coupled to thesurgical instrument 2000. In some embodiments, one or more safety valuesstored by the safety processor 1104 are duplicated by the primaryprocessor 1106. Two-way error detection is performed to ensure valuesand/or parameters stored by either of the processors 1104, 1106 arecorrect.

In some embodiments, the safety processor 1104 and the primary processor1106 implement a redundant safety check. The safety processor 1104 andthe primary processor 1106 provide periodic signals indicating normaloperation. For example, during operation, the safety processor 1104 mayindicate to the primary processor 1106 that the safety processor 1104 isexecuting code and operating normally. The primary processor 1106 may,likewise, indicate to the safety processor 1104 that the primaryprocessor 1106 is executing code and operating normally. In someembodiments, communication between the safety processor 1104 and theprimary processor 1106 occurs at a predetermined interval. Thepredetermined interval may be constant or may be variable based on thecircuit state and/or operation of the surgical instrument 2000.

FIG. 7 is a block diagram illustrating a safety process 1250 configuredto be implemented by a safety processor, such as, for example, thesafety process 1104 illustrated in FIGS. 5A and 5B. In one embodiment,values corresponding to a plurality of properties of a surgicalinstrument 2000 are provided to the safety processor 1104. The pluralityof properties is monitored by a plurality of independent sensors and/orsystems. For example, in the illustrated embodiment, a measured cuttingmember speed 1252, a propositional motor speed 1254, and an intendeddirection of motor signal 1256 are provided to a safety processor 1104.The cutting member speed 1252 and the propositional motor speed 1254 maybe provided by independent sensors, such as, for example, a linear hallsensor and a current sensor respectively. The intended direction ofmotor signal 1256 may be provided by a primary processor, for example,the primary processor 1106 illustrated in FIGS. 5A and 5B. The safetyprocessor 1104 compares 1258 the plurality of properties and determineswhen the properties are consistent with a predetermined relationship.When the plurality of properties comprises values consistent with thepredetermined relationship 1260 a, no action is taken 1262. When theplurality of properties comprises values inconsistent with thepredetermined relationship 1260 b, the safety processor 1104 executesone or more actions, such as, for example, blocking a function,executing a function, and/or resetting a processor. For example, in theprocess 1250 illustrated in FIG. 7, the safety processor 1104 interruptsoperation of one or more circuit segments, such as, for example, byinterrupting power 1264 to a motor segment.

Referring back to FIGS. 5A and 5B, the segmented circuit 1100 comprisesa plurality of switches 1156-1170 configured to control one or moreoperations of the surgical instrument 2000. For example, in theillustrated embodiment, the segmented circuit 1100 comprises a clamprelease switch 1168, a firing trigger 1166, and a plurality of switches1158 a-1164 b configured to control articulation of a shaft 2004 and/orend effector 2006 coupled to the surgical instrument 2000. The clamprelease switch 1168, the fire trigger 1166, and the plurality ofarticulation switches 1158 a-1164 b may comprise analog and/or digitalswitches. In particular, switch 1156 indicates the mechanical switchlifter down position, switches 1158 a, 1158 b indicate articulate left(1) and (2), switch 1160 a, 1160 b indicate articulate right (1) and(2), switches 1162 a, 1162 b indicate articulate center (1) and (2), andswitches 1164 a, 1164 b indicate reverse/left and reverse/right.

For example, FIG. 8 illustrates one embodiment of a switch bank 1300comprising a plurality of switches SW1-SW16 configured to control one ormore operations of a surgical instrument. The switch bank 1300 may becoupled to a primary processor, such as, for example, the primaryprocessor 1106. In some embodiments, one or more diodes D1-D8 arecoupled to the plurality of switches SW1-SW16. Any suitable mechanical,electromechanical, or solid state switches may be employed to implementthe plurality of switches 1156-1170, in any combination. For example,the switches 1156-1170 may limit switches operated by the motion ofcomponents associated with the surgical instrument 2000 or the presenceof an object. Such switches may be employed to control various functionsassociated with the surgical instrument 2000. A limit switch is anelectromechanical device that consists of an actuator mechanicallylinked to a set of contacts. When an object comes into contact with theactuator, the device operates the contacts to make or break anelectrical connection. Limit switches are used in a variety ofapplications and environments because of their ruggedness, ease ofinstallation, and reliability of operation. They can determine thepresence or absence, passing, positioning, and end of travel of anobject. In other implementations, the switches 1156-1170 may be solidstate switches that operate under the influence of a magnetic field suchas Hall-effect devices, magneto-resistive (MR) devices, giantmagneto-resistive (GMR) devices, magnetometers, among others. In otherimplementations, the switches 1156-1170 may be solid state switches thatoperate under the influence of light, such as optical sensors, infraredsensors, ultraviolet sensors, among others. Still, the switches1156-1170 may be solid state devices such as transistors (e.g., FET,Junction-FET, metal-oxide semiconductor-FET (MOSFET), bipolar, and thelike). Other switches may include wireless switches, ultrasonicswitches, accelerometers, inertial sensors, among others.

FIG. 9 illustrates one embodiment of a switch bank 1350 comprising aplurality of switches. In various embodiments, one or more switches areconfigured to control one or more operations of a surgical instrument,such as, for example, the surgical instrument 2000 illustrated in FIGS.1-3B. A plurality of articulation switches SW1-SW16 is configured tocontrol articulation of a shaft 2004 and/or an end effector 2006 coupledto the surgical instrument 2000. A firing trigger 1366 is configured tofire the surgical instrument 2000, for example, to deploy a plurality ofstaples, translate a cutting member within the end effector 2006, and/ordeliver electrosurgical energy to the end effector 2006. In someembodiments, the switch bank 1350 comprises one or more safety switchesconfigured to prevent operation of the surgical instrument 2000. Forexample, a bailout switch 1356 is coupled to a bailout door and preventsoperation of the surgical instrument 2000 when the bailout door is in anopen position.

FIGS. 10A and 10B illustrate one embodiment of a segmented circuit 1400comprising a switch bank 1450 coupled to the primary processor 1406. Theswitch bank 1450 is similar to the switch bank 1350 illustrated in FIG.9. The switch bank 1450 comprises a plurality of switches SW1-SW16configured to control one or more operations of a surgical instrument,such as, for example, the surgical instrument 2000 illustrated in FIGS.1-3B. The switch bank 1450 is coupled to an analog input of the primaryprocessor 1406. Each of the switches within the switch bank 1450 isfurther coupled to an input/output expander 1463 coupled to a digitalinput of the primary processor 1406. The primary processor 1406 receivesinput from the switch bank 1450 and controls one or more additionalsegments of the segmented circuit 1400, such as, for example, a motorsegment 1402 g in response to manipulation of one or more switches ofthe switch bank 1450.

In some embodiments, a potentiometer 1469 is coupled to the primaryprocessor 1406 to provide a signal indicative of a clamp position of anend effector 2006 coupled to the surgical instrument 2000. Thepotentiometer 1469 may replace and/or supplement a safety processor (notshown) by providing a signal indicative of a clamp open/closed positionused by the primary processor 1106 to control operation of one or morecircuit segments, such as, for example, the motor segment 1102 g. Forexample, when the potentiometer 1469 indicates that the end effector isin a fully clamped position and/or a fully open position, the primaryprocessor 1406 may open the motor power switch 1420 and prevent furtheroperation of the motor segment 1402 g in a specific direction. In someembodiments, the primary processor 1406 controls the current deliveredto the motor segment 1402 g in response to a signal received from thepotentiometer 1469. For example, the primary processor 1406 may limitthe energy that can be delivered to the motor segment 1402 g when thepotentiometer 1469 indicates that the end effector is closed beyond apredetermined position.

Referring back to FIGS. 5A and 5B, the segmented circuit 1100 comprisesan acceleration segment 1102c. The acceleration segment comprises anaccelerometer 1122. The accelerometer 1122 may be coupled to the safetyprocessor 1104 and/or the primary processor 1106. The accelerometer 1122is configured to monitor movement of the surgical instrument 2000. Theaccelerometer 1122 is configured to generate one or more signalsindicative of movement in one or more directions. For example, in someembodiments, the accelerometer 1122 is configured to monitor movement ofthe surgical instrument 2000 in three directions. In other embodiments,the acceleration segment 1102 c comprises a plurality of accelerometers1122, each configured to monitor movement in a signal direction.

In some embodiments, the accelerometer 1122 is configured to initiate atransition to and/or from a sleep mode, e.g., between sleep-mode andwake-up mode and vice versa. Sleep mode may comprise a low-power mode inwhich one or more of the circuit segments 1102 a-1102 g are deactivatedor placed in a low-power state. For example, in one embodiment, theaccelerometer 1122 remains active in sleep mode and the safety processor1104 is placed into a low-power mode in which the safety processor 1104monitors the accelerometer 1122, but otherwise does not perform anyfunctions. The remaining circuit segments 1102 b-1102 g are powered off.In various embodiments, the primary processor 1104 and/or the safetyprocessor 1106 are configured to monitor the accelerometer 1122 andtransition the segmented circuit 1100 to sleep mode, for example, whenno movement is detected within a predetermined time period. Althoughdescribed in connection with the safety processor 1104 monitoring theaccelerometer 1122, the sleep-mode/wake-up mode may be implemented bythe safety processor 1104 monitoring any of the sensors, switches, orother indicators associated with the surgical instrument 2000 asdescribed herein. For example, the safety processor 1104 may monitor aninertial sensor, or a one or more switches.

In some embodiments, the segmented circuit 1100 transitions to sleepmode after a predetermined period of inactivity. A timer is in signalcommunication with the safety processor 1104 and/or the primaryprocessor 1106. The timer may be integral with the safety processor1104, the primary processor 1106, and/or may be a separate circuitcomponent. The timer is configured to monitor a time period since a lastmovement of the surgical instrument 2000 was detected by theaccelerometer 1122. When the counter exceeds a predetermined threshold,the safety processor 1104 and/or the primary processor 1106 transitionsthe segmented circuit 1100 into sleep mode. In some embodiments, thetimer is reset each time the accelerometer 1122 detects movement.

In some embodiments, all circuit segments except the accelerometer 1122,or other designated sensors and/or switches, and the safety processor1104 are deactivated when in sleep mode. The safety processor 1104monitors the accelerometer 1122, or other designated sensors and/orswitches. When the accelerometer 1122 indicates movement of the surgicalinstrument 2000, the safety processor 1104 initiates a transition fromsleep mode to operational mode. In operational mode, all of the circuitsegments 1102 a-1102 h are fully energized and the surgical instrument2000 is ready for use. In some embodiments, the safety processor 1104transitions the segmented circuit 1100 to the operational mode byproviding a signal to the primary processor 1106 to transition theprimary processor 1106 from sleep mode to a full power mode. The primaryprocessor 1106, then transitions each of the remaining circuit segments1102 d-1102 h to operational mode.

The transition to and/or from sleep mode may comprise a plurality ofstages. For example, in one embodiment, the segmented circuit 1100transitions from the operational mode to the sleep mode in four stages.The first stage is initiated after the accelerometer 1122 has notdetected movement of the surgical instrument for a first predeterminedtime period. After the first predetermined time period the segmentedcircuit 1100 dims a backlight of the display segment 1102 d. When nomovement is detected within a second predetermined period, the safetyprocessor 1104 transitions to a second stage, in which the backlight ofthe display segment 1102 d is turned off. When no movement is detectedwithin a third predetermined time period, the safety processor 1104transitions to a third stage, in which the polling rate of theaccelerometer 1122 is reduced. When no movement is detected within afourth predetermined time period, the display segment 1102 d isdeactivated and the segmented circuit 1100 enters sleep mode. In sleepmode, all of the circuit segments except the accelerometer 1122 and thesafety processor 1104 are deactivated. The safety processor 1104 entersa low-power mode in which the safety processor 1104 only polls theaccelerometer 1122. The safety processor 1104 monitors the accelerometer1122 until the accelerometer 1122 detects movement, at which point thesafety processor 1104 transitions the segmented circuit 1100 from sleepmode to the operational mode.

In some embodiments, the safety processor 1104 transitions the segmentedcircuit 1100 to the operational mode only when the accelerometer 1122detects movement of the surgical instrument 2000 above a predeterminedthreshold. By responding only to movement above a predeterminedthreshold, the safety processor 1104 prevents inadvertent transition ofthe segmented circuit 1100 to operational mode when the surgicalinstrument 2000 is bumped or moved while stored. In some embodiments,the accelerometer 1122 is configured to monitor movement in a pluralityof directions. For example, the accelerometer 1122 may be configured todetect movement in a first direction and a second direction. The safetyprocessor 1104 monitors the accelerometer 1122 and transitions thesegmented circuit 1100 from sleep mode to operational mode when movementabove a predetermined threshold is detected in both the first directionand the second direction. By requiring movement above a predeterminedthreshold in at least two directions, the safety processor 1104 isconfigured to prevent inadvertent transition of the segmented circuit1100 from sleep mode due to incidental movement during storage.

In some embodiments, the accelerometer 1122 is configured to detectmovement in a first direction, a second direction, and a thirddirection. The safety processor 1104 monitors the accelerometer 1122 andis configured to transition the segmented circuit 1100 from sleep modeonly when the accelerometer 1122 detects oscillating movement in each ofthe first direction, second direction, and third direction. In someembodiments, oscillating movement in each of a first direction, a seconddirection, and a third direction correspond to movement of the surgicalinstrument 2000 by an operator and therefore transition to theoperational mode is desirable when the accelerometer 1122 detectsoscillating movement in three directions.

In some embodiments, as the time since the last movement detectedincreases, the predetermined threshold of movement required totransition the segmented circuit 1100 from sleep mode also increases.For example, in some embodiments, the timer continues to operate duringsleep mode. As the timer count increases, the safety processor 1104increases the predetermined threshold of movement required to transitionthe segmented circuit 1100 to operational mode. The safety processor1104 may increase the predetermined threshold to an upper limit. Forexample, in some embodiments, the safety processor 1104 transitions thesegmented circuit 1100 to sleep mode and resets the timer. Thepredetermined threshold of movement is initially set to a low value,requiring only a minor movement of the surgical instrument 2000 totransition the segmented circuit 1100 from sleep mode. As the time sincethe transition to sleep mode, as measured by the timer, increases, thesafety processor 1104 increases the predetermined threshold of movement.At a time T, the safety processor 1104 has increased the predeterminedthreshold to an upper limit. For all times T+, the predeterminedthreshold maintains a constant value of the upper limit.

In some embodiments, one or more additional and/or alternative sensorsare used to transition the segmented circuit 1100 between sleep mode andoperational mode. For example, in one embodiment, a touch sensor islocated on the surgical instrument 2000. The touch sensor is coupled tothe safety processor 1104 and/or the primary processor 1106. The touchsensor is configured to detect user contact with the surgical instrument2000. For example, the touch sensor may be located on the handle of thesurgical instrument 2000 to detect when an operator picks up thesurgical instrument 2000. The safety processor 1104 transitions thesegmented circuit 1100 to sleep mode after a predetermined period haspassed without the accelerometer 1122 detecting movement. The safetyprocessor 1104 monitors the touch sensor and transitions the segmentedcircuit 1100 to operational mode when the touch sensor detects usercontact with the surgical instrument 2000. The touch sensor maycomprise, for example, a capacitive touch sensor, a temperature sensor,and/or any other suitable touch sensor. In some embodiments, the touchsensor and the accelerometer 1122 may be used to transition the devicebetween sleep mode and operation mode. For example, the safety processor1104 may only transition the device to sleep mode when the accelerometer1122 has not detected movement within a predetermined period and thetouch sensor does not indicate a user is in contact with the surgicalinstrument 2000. Those skilled in the art will recognize that one ormore additional sensors may be used to transition the segmented circuit1100 between sleep mode and operational mode. In some embodiments, thetouch sensor is only monitored by the safety processor 1104 when thesegmented circuit 1100 is in sleep mode.

In some embodiments, the safety processor 1104 is configured totransition the segmented circuit 1100 from sleep mode to the operationalmode when one or more handle controls are actuated. After transitioningto sleep mode, such as, for example, after the accelerometer 1122 hasnot detected movement for a predetermined period, the safety processor1104 monitors one or more handle controls, such as, for example, theplurality of articulation switches 1158 a-1164 b. In other embodiments,the one or more handle controls comprise, for example, a clamp control1166, a release button 1168, and/or any other suitable handle control.An operator of the surgical instrument 2000 may actuate one or more ofthe handle controls to transition the segmented circuit 1100 tooperational mode. When the safety processor 1104 detects the actuationof a handle control, the safety processor 1104 initiates the transitionof the segmented circuit 1100 to operational mode. Because the primaryprocessor 1106 is in not active when the handle control is actuated, theoperator can actuate the handle control without causing a correspondingaction of the surgical instrument 2000.

FIG. 16 illustrates one embodiment of a segmented circuit 1900comprising an accelerometer 1922 configured to monitor movement of asurgical instrument, such as, for example, the surgical instrument 2000illustrated in FIGS. 1-3B. A power segment 1902 provides power from abattery 1908 to one or more circuit segments, such as, for example, theaccelerometer 1922. The accelerometer 1922 is coupled to a processor1906. The accelerometer 1922 is configured to monitor movement thesurgical instrument 2000. The accelerometer 1922 is configured togenerate one or more signals indicative of movement in one or moredirections. For example, in some embodiments, the accelerometer 1922 isconfigured to monitor movement of the surgical instrument 2000 in threedirections.

In certain instances, the processor 1906 may be an LM4F230H5QR,available from Texas Instruments, for example. The processor 1906 isconfigured to monitor the accelerometer 1922 and transition thesegmented circuit 1900 to sleep mode, for example, when no movement isdetected within a predetermined time period. In some embodiments, thesegmented circuit 1900 transitions to sleep mode after a predeterminedperiod of inactivity. For example, a safety processor 1904 maytransitions the segmented circuit 1900 to sleep mode after apredetermined period has passed without the accelerometer 1922 detectingmovement. In certain instances, the accelerometer 1922 may be anLIS331DLM, available from STMicroelectronics, for example. A timer is insignal communication with the processor 1906. The timer may be integralwith the processor 1906 and/or may be a separate circuit component. Thetimer is configured to count time since a last movement of the surgicalinstrument 2000 was detected by the accelerometer 1922. When the counterexceeds a predetermined threshold, the processor 1906 transitions thesegmented circuit 1900 into sleep mode. In some embodiments, the timeris reset each time the accelerometer 1922 detects movement.

In some embodiments, the accelerometer 1922 is configured to detect animpact event. For example, when a surgical instrument 2000 is dropped,the accelerometer 1922 will detect acceleration due to gravity in afirst direction and then a change in acceleration in a second direction(caused by impact with a floor and/or other surface). As anotherexample, when the surgical instrument 2000 impacts a wall, theaccelerometer 1922 will detect a spike in acceleration in one or moredirections. When the accelerometer 1922 detects an impact event, theprocessor 1906 may prevent operation of the surgical instrument 2000, asimpact events can loosen mechanical and/or electrical components. Insome embodiments, only impacts above a predetermined threshold preventoperation. In other embodiments, all impacts are monitored andcumulative impacts above a predetermined threshold may prevent operationof the surgical instrument 2000.

With reference back to FIGS. 5A and 5B, in one embodiment, the segmentedcircuit 1100 comprises a power segment 1102 h. The power segment 1102 his configured to provide a segment voltage to each of the circuitsegments 1102 a-1102 g. The power segment 1102 h comprises a battery1108. The battery 1108 is configured to provide a predetermined voltage,such as, for example, 12 volts through battery connector 1110. One ormore power converters 1114 a, 1114 b, 1116 are coupled to the battery1108 to provide a specific voltage. For example, in the illustratedembodiments, the power segment 1102 h comprises an axillary switchingconverter 1114 a, a switching converter 1114 b, and a low-drop out (LDO)converter 1116. The switch converters 1114 a, 1114 b are configured toprovide 3.3 volts to one or more circuit components. The LDO converter1116 is configured to provide 5.0 volts to one or more circuitcomponents. In some embodiments, the power segment 1102 h comprises aboost converter 1118. A transistor switch (e.g., N-Channel MOSFET) 1115is coupled to the power converters 1114 b, 1116. The boost converter1118 is configured to provide an increased voltage above the voltageprovided by the battery 1108, such as, for example, 13 volts. The boostconverter 1118 may comprise, for example, a capacitor, an inductor, abattery, a rechargeable battery, and/or any other suitable boostconverter for providing an increased voltage. The boost converter 1118provides a boosted voltage to prevent brownouts and/or low-powerconditions of one or more circuit segments 1102 a-1102 g duringpower-intensive operations of the surgical instrument 2000. Theembodiments, however, are not limited to the voltage range(s) describedin the context of this specification.

In some embodiments, the segmented circuit 1100 is configured forsequential start-up. An error check is performed by each circuit segment1102 a-1102 g prior to energizing the next sequential circuit segment1102 a-1102 g. FIG. 11 illustrates one embodiment of a process forsequentially energizing a segmented circuit 1270, such as, for example,the segmented circuit 1100. When a battery 1108 is coupled to thesegmented circuit 1100, the safety processor 1104 is energized 1272. Thesafety processor 1104 performs a self-error check 1274. When an error isdetected 1276 a, the safety processor stops energizing the segmentedcircuit 1100 and generates an error code 1278 a. When no errors aredetected 1276 b, the safety processor 1104 initiates 1278 b power-up ofthe primary processor 1106. The primary processor 1106 performs aself-error check. When no errors are detected, the primary processor1106 begins sequential power-up of each of the remaining circuitsegments 1278 b. Each circuit segment is energized and error checked bythe primary processor 1106. When no errors are detected, the nextcircuit segment is energized 1278 b. When an error is detected, thesafety processor 1104 and/or the primary process stops energizing thecurrent segment and generates an error 1278 a. The sequential start-upcontinues until all of the circuit segments 1102 a-1102 g have beenenergized. In some embodiments, the segmented circuit 1100 transitionsfrom sleep mode following a similar sequential power-up process 1250.

FIG. 12 illustrates one embodiment of a power segment 1502 comprising aplurality of daisy chained power converters 1514, 1516, 1518. The powersegment 1502 comprises a battery 1508. The battery 1508 is configured toprovide a source voltage, such as, for example, 12V. A current sensor1512 is coupled to the battery 1508 to monitor the current draw of asegmented circuit and/or one or more circuit segments. The currentsensor 1512 is coupled to an FET switch 1513. The battery 1508 iscoupled to one or more voltage converters 1509, 1514, 1516. An always onconverter 1509 provides a constant voltage to one or more circuitcomponents, such as, for example, a motion sensor 1522. The always onconverter 1509 comprises, for example, a 3.3V converter. The always onconverter 1509 may provide a constant voltage to additional circuitcomponents, such as, for example, a safety processor (not shown). Thebattery 1508 is coupled to a boost converter 1518. The boost converter1518 is configured to provide a boosted voltage above the voltageprovided by the battery 1508. For example, in the illustratedembodiment, the battery 1508 provides a voltage of 12V. The boostconverter 1518 is configured to boost the voltage to 13V. The boostconverter 1518 is configured to maintain a minimum voltage duringoperation of a surgical instrument, for example, the surgical instrument2000 illustrated in FIGS. 1-3B. Operation of a motor can result in thepower provided to the primary processor 1506 dropping below a minimumthreshold and creating a brownout or reset condition in the primaryprocessor 1506. The boost converter 1518 ensures that sufficient poweris available to the primary processor 1506 and/or other circuitcomponents, such as the motor controller 1543, during operation of thesurgical instrument 2000. In some embodiments, the boost converter 1518is coupled directly one or more circuit components, such as, forexample, an OLED display 1588.

The boost converter 1518 is coupled to a one or more step-downconverters to provide voltages below the boosted voltage level. A firstvoltage converter 1516 is coupled to the boost converter 1518 andprovides a first stepped-down voltage to one or more circuit components.In the illustrated embodiment, the first voltage converter 1516 providesa voltage of 5V. The first voltage converter 1516 is coupled to a rotaryposition encoder 1540. A FET switch 1517 is coupled between the firstvoltage converter 1516 and the rotary position encoder 1540. The FETswitch 1517 is controlled by the processor 1506. The processor 1506opens the FET switch 1517 to deactivate the position encoder 1540, forexample, during power intensive operations. The first voltage converter1516 is coupled to a second voltage converter 1514 configured to providea second stepped-down voltage. The second stepped-down voltagecomprises, for example, 3.3V. The second voltage converter 1514 iscoupled to a processor 1506. In some embodiments, the boost converter1518, the first voltage converter 1516, and the second voltage converter1514 are coupled in a daisy chain configuration. The daisy chainconfiguration allows the use of smaller, more efficient converters forgenerating voltage levels below the boosted voltage level. Theembodiments, however, are not limited to the particular voltage range(s)described in the context of this specification.

FIG. 13 illustrates one embodiment of a segmented circuit 1600configured to maximize power available for critical and/or power intensefunctions. The segmented circuit 1600 comprises a battery 1608. Thebattery 1608 is configured to provide a source voltage such as, forexample, 12V. The source voltage is provided to a plurality of voltageconverters 1619, 1618. An always-on voltage converter 1619 provides aconstant voltage to one or more circuit components, for example, amotion sensor 1622 and a safety processor 1604. The always-on voltageconverter 1619 is directly coupled to the battery 1608. The always-onconverter 1619 provides a voltage of, for example, 3.3V. Theembodiments, however, are not limited to the particular voltage range(s)described in the context of this specification.

The segmented circuit 1600 comprises a boost converter 1618. The boostconverter 1618 provides a boosted voltage above the source voltageprovided by the battery 1608, such as, for example, 13V. The boostconverter 1618 provides a boosted voltage directly to one or morecircuit components, such as, for example, an OLED display 1688 and amotor controller 1643. By coupling the OLED display 1688 directly to theboost converter 1618, the segmented circuit 1600 eliminates the need fora power converter dedicated to the OLED display 1688. The boostconverter 1618 provides a boosted voltage to the motor controller 1643and the motor 1648 during one or more power intensive operations of themotor 1648, such as, for example, a cutting operation. The boostconverter 1618 is coupled to a step-down converter 1616. The step-downconverter 1616 is configured to provide a voltage below the boostedvoltage to one or more circuit components, such as, for example, 5V. Thestep-down converter 1616 is coupled to, for example, an FET switch 1651and a position encoder 1640. The FET switch 1651 is coupled to theprimary processor 1606. The primary processor 1606 opens the FET switch1651 when transitioning the segmented circuit 1600 to sleep mode and/orduring power intensive functions requiring additional voltage deliveredto the motor 1648. Opening the FET switch 1651 deactivates the positionencoder 1640 and eliminates the power draw of the position encoder 1640.The embodiments, however, are not limited to the particular voltagerange(s) described in the context of this specification.

The step-down converter 1616 is coupled to a linear converter 1614. Thelinear converter 1614 is configured to provide a voltage of, forexample, 3.3V. The linear converter 1614 is coupled to the primaryprocessor 1606. The linear converter 1614 provides an operating voltageto the primary processor 1606. The linear converter 1614 may be coupledto one or more additional circuit components. The embodiments, however,are not limited to the particular voltage range(s) described in thecontext of this specification.

The segmented circuit 1600 comprises a bailout switch 1656. The bailoutswitch 1656 is coupled to a bailout door on the surgical instrument2000. The bailout switch 1656 and the safety processor 1604 are coupledto an AND gate 1609. The AND gate 1609 provides an input to a FET switch1613. When the bailout switch 1656 detects a bailout condition, thebailout switch 1656 provides a bailout shutdown signal to the AND gate1609. When the safety processor 1604 detects an unsafe condition, suchas, for example, due to a sensor mismatch, the safety processor 1604provides a shutdown signal to the AND gate 1609. In some embodiments,both the bailout shutdown signal and the shutdown signal are high duringnormal operation and are low when a bailout condition or an unsafecondition is detected. When the output of the AND gate 1609 is low, theFET switch 1613 is opened and operation of the motor 1648 is prevented.In some embodiments, the safety processor 1604 utilizes the shutdownsignal to transition the motor 1648 to an off state in sleep mode. Athird input to the FET switch 1613 is provided by a current sensor 1612coupled to the battery 1608. The current sensor 1612 monitors thecurrent drawn by the circuit 1600 and opens the FET switch 1613 toshut-off power to the motor 1648 when an electrical current above apredetermined threshold is detected. The FET switch 1613 and the motorcontroller 1643 are coupled to a bank of FET switches 1645 configured tocontrol operation of the motor 1648.

A motor current sensor 1646 is coupled in series with the motor 1648 toprovide a motor current sensor reading to a current monitor 1647. Thecurrent monitor 1647 is coupled to the primary processor 1606. Thecurrent monitor 1647 provides a signal indicative of the current draw ofthe motor 1648. The primary processor 1606 may utilize the signal fromthe motor current 1647 to control operation of the motor, for example,to ensure the current draw of the motor 1648 is within an acceptablerange, to compare the current draw of the motor 1648 to one or moreother parameters of the circuit 1600 such as, for example, the positionencoder 1640, and/or to determine one or more parameters of a treatmentsite. In some embodiments, the current monitor 1647 may be coupled tothe safety processor 1604.

In some embodiments, actuation of one or more handle controls, such as,for example, a firing trigger, causes the primary processor 1606 todecrease power to one or more components while the handle control isactuated. For example, in one embodiment, a firing trigger controls afiring stroke of a cutting member. The cutting member is driven by themotor 1648. Actuation of the firing trigger results in forward operationof the motor 1648 and advancement of the cutting member. During firing,the primary processor 1606 closes the FET switch 1651 to remove powerfrom the position encoder 1640. The deactivation of one or more circuitcomponents allows higher power to be delivered to the motor 1648. Whenthe firing trigger is released, full power is restored to thedeactivated components, for example, by closing the FET switch 1651 andreactivating the position encoder 1640.

In some embodiments, the safety processor 1604 controls operation of thesegmented circuit 1600. For example, the safety processor 1604 mayinitiate a sequential power-up of the segmented circuit 1600, transitionof the segmented circuit 1600 to and from sleep mode, and/or mayoverride one or more control signals from the primary processor 1606.For example, in the illustrated embodiment, the safety processor 1604 iscoupled to the step-down converter 1616. The safety processor 1604controls operation of the segmented circuit 1600 by activating ordeactivating the step-down converter 1616 to provide power to theremainder of the segmented circuit 1600.

FIG. 14 illustrates one embodiment of a power system 1700 comprising aplurality of daisy chained power converters 1714, 1716, 1718 configuredto be sequentially energized. The plurality of daisy chained powerconverters 1714, 1716, 1718 may be sequentially activated by, forexample, a safety processor during initial power-up and/or transitionfrom sleep mode. The safety processor may be powered by an independentpower converter (not shown). For example, in one embodiment, when abattery voltage V_(BATT) is coupled to the power system 1700 and/or anaccelerometer detects movement in sleep mode, the safety processorinitiates a sequential start-up of the daisy chained power converters1714, 1716, 1718. The safety processor activates the 13V boost section1718. The boost section 1718 is energized and performs a self-check. Insome embodiments, the boost section 1718 comprises an integrated circuit1720 configured to boost the source voltage and to perform a self check.A diode D prevents power-up of a 5V supply section 1716 until the boostsection 1718 has completed a self-check and provided a signal to thediode D indicating that the boost section 1718 did not identify anyerrors. In some embodiments, this signal is provided by the safetyprocessor. The embodiments, however, are not limited to the particularvoltage range(s) described in the context of this specification.

The 5V supply section 1716 is sequentially powered-up after the boostsection 1718. The 5V supply section 1716 performs a self-check duringpower-up to identify any errors in the 5V supply section 1716. The 5Vsupply section 1716 comprises an integrated circuit 1715 configured toprovide a step-down voltage from the boost voltage and to perform anerror check. When no errors are detected, the 5V supply section 1716completes sequential power-up and provides an activation signal to the3.3V supply section 1714. In some embodiments, the safety processorprovides an activation signal to the 3.3V supply section 1714. The 3.3Vsupply section comprises an integrated circuit 1713 configured toprovide a step-down voltage from the 5V supply section 1716 and performa self-error check during power-up. When no errors are detected duringthe self-check, the 3.3V supply section 1714 provides power to theprimary processor. The primary processor is configured to sequentiallyenergize each of the remaining circuit segments. By sequentiallyenergizing the power system 1700 and/or the remainder of a segmentedcircuit, the power system 1700 reduces error risks, allows forstabilization of voltage levels before loads are applied, and preventslarge current draws from all hardware being turned on simultaneously inan uncontrolled manner. The embodiments, however, are not limited to theparticular voltage range(s) described in the context of thisspecification.

In one embodiment, the power system 1700 comprises an over voltageidentification and mitigation circuit. The over voltage identificationand mitigation circuit is configured to detect a monopolar returncurrent in the surgical instrument and interrupt power from the powersegment when the monopolar return current is detected. The over voltageidentification and mitigation circuit is configured to identify groundfloatation of the power system. The over voltage identification andmitigation circuit comprises a metal oxide varistor. The over voltageidentification and mitigation circuit comprises at least one transientvoltage suppression diode.

FIG. 15 illustrates one embodiment of a segmented circuit 1800comprising an isolated control section 1802. The isolated controlsection 1802 isolates control hardware of the segmented circuit 1800from a power section (not shown) of the segmented circuit 1800. Thecontrol section 1802 comprises, for example, a primary processor 1806, asafety processor (not shown), and/or additional control hardware, forexample, a FET Switch 1817. The power section comprises, for example, amotor, a motor driver, and/or a plurality of motor MOSFETS. The isolatedcontrol section 1802 comprises a charging circuit 1803 and arechargeable battery 1808 coupled to a 5V power converter 1816. Thecharging circuit 1803 and the rechargeable battery 1808 isolate theprimary processor 1806 from the power section. In some embodiments, therechargeable battery 1808 is coupled to a safety processor and anyadditional support hardware. Isolating the control section 1802 from thepower section allows the control section 1802, for example, the primaryprocessor 1806, to remain active even when main power is removed,provides a filter, through the rechargeable battery 1808, to keep noiseout of the control section 1802, isolates the control section 1802 fromheavy swings in the battery voltage to ensure proper operation evenduring heavy motor loads, and/or allows for real-time operating system(RTOS) to be used by the segmented circuit 1800. In some embodiments,the rechargeable battery 1808 provides a stepped-down voltage to theprimary processor, such as, for example, 3.3V. The embodiments, however,are not limited to the particular voltage range(s) described in thecontext of this specification.

FIG. 17 illustrates one embodiment of a process for sequential start-upof a segmented circuit, such as, for example, the segmented circuit 1100illustrated in FIGS. 5A and 5B. The sequential start-up process 1820begins when one or more sensors initiate a transition from sleep mode tooperational mode. When the one or more sensors stop detecting statechanges 1822, a timer is started 1824. The timer counts the time sincethe last movement/interaction with the surgical instrument 2000 wasdetected by the one or more sensors. The timer count is compared 1826 toa table of sleep mode stages by, for example, the safety processor 1104.When the timer count exceeds one or more counts for transition to asleep mode stage 1828 a, the safety processor 1104 stops energizing 1830the segmented circuit 1100 and transitions the segmented circuit 1100 tothe corresponding sleep mode stage. When the timer count is below thethreshold for any of the sleep mode stages 1828 b, the segmented circuit1100 continues to sequentially energize the next circuit segment 1832.

With reference back to FIGS. 5A and 5B, in some embodiments, thesegmented circuit 1100 comprises one or more environmental sensors todetect improper storage and/or treatment of a surgical instrument. Forexample, in one embodiment, the segmented circuit 1100 comprises atemperature sensor. The temperature sensor is configured to detect themaximum and/or minimum temperature that the segmented circuit 1100 isexposed to. The surgical instrument 2000 and the segmented circuit 1100comprise a design limit exposure for maximum and/or minimumtemperatures. When the surgical instrument 2000 is exposed totemperatures exceeding the limits, for example, a temperature exceedingthe maximum limit during a sterilization technique, the temperaturesensor detects the overexposure and prevents operation of the device.The temperature sensor may comprise, for example, a bi-metal stripconfigured to disable the surgical instrument 2000 when exposed to atemperature above a predetermined threshold, a solid-state temperaturesensor configured to store temperature data and provide the temperaturedata to the safety processor 1104, and/or any other suitable temperaturesensor.

In some embodiments, the accelerometer 1122 is configured as anenvironmental safety sensor. The accelerometer 1122 records theacceleration experienced by the surgical instrument 2000. Accelerationabove a predetermined threshold may indicate, for example, that thesurgical instrument has been dropped. The surgical instrument comprisesa maximum acceleration tolerance. When the accelerometer 1122 detectsacceleration above the maximum acceleration tolerance, safety processor1104 prevents operation of the surgical instrument 2000.

In some embodiments, the segmented circuit 1100 comprises a moisturesensor. The moisture sensor is configured to indicate when the segmentedcircuit 1100 has been exposed to moisture. The moisture sensor maycomprise, for example, an immersion sensor configured to indicate whenthe surgical instrument 2000 has been fully immersed in a cleaningfluid, a moisture sensor configured to indicate when moisture is incontact with the segmented circuit 1100 when the segmented circuit 1100is energized, and/or any other suitable moisture sensor.

In some embodiments, the segmented circuit 1100 comprises a chemicalexposure sensor. The chemical exposure sensor is configured to indicatewhen the surgical instrument 2000 has come into contact with harmfuland/or dangerous chemicals. For example, during a sterilizationprocedure, an inappropriate chemical may be used that leads todegradation of the surgical instrument 2000. The chemical exposuresensor may indicate inappropriate chemical exposure to the safetyprocessor 1104, which may prevent operation of the surgical instrument2000.

The segmented circuit 1100 is configured to monitor a number of usagecycles. For example, in one embodiment, the battery 1108 comprises acircuit configured to monitor a usage cycle count. In some embodiments,the safety processor 1104 is configured to monitor the usage cyclecount. Usage cycles may comprise surgical events initiated by a surgicalinstrument, such as, for example, the number of shafts 2004 used withthe surgical instrument 2000, the number of cartridges inserted intoand/or deployed by the surgical instrument 2000, and/or the number offirings of the surgical instrument 2000. In some embodiments, a usagecycle may comprise an environmental event, such as, for example, animpact event, exposure to improper storage conditions and/or improperchemicals, a sterilization process, a cleaning process, and/or areconditioning process. In some embodiments, a usage cycle may comprisea power assembly (e.g., battery pack) exchange and/or a charging cycle.

The segmented circuit 1100 may maintain a total usage cycle count forall defined usage cycles and/or may maintain individual usage cyclecounts for one or more defined usage cycles. For example, in oneembodiment, the segmented circuit 1100 may maintain a single usage cyclecount for all surgical events initiated by the surgical instrument 2000and individual usage cycle counts for each environmental eventexperienced by the surgical instrument 2000. The usage cycle count isused to enforce one or more behaviors by the segmented circuit 1100. Forexample, usage cycle count may be used to disable a segmented circuit1100, for example, by disabling a battery 1108, when the number of usagecycles exceeds a predetermined threshold or exposure to an inappropriateenvironmental event is detected. In some embodiments, the usage cyclecount is used to indicate when suggested and/or mandatory service of thesurgical instrument 2000 is necessary.

FIG. 18 illustrates one embodiment of a method 1950 for controlling asurgical instrument comprising a segmented circuit, such as, forexample, the segmented control circuit 1602 illustrated in FIG. 12. At1952, a power assembly 1608 is coupled to the surgical instrument. Thepower assembly 1608 may comprise any suitable battery, such as, forexample, the power assembly 2006 illustrates in FIGS. 1-3B. The powerassembly 1608 is configured to provide a source voltage to the segmentedcontrol circuit 1602. The source voltage may comprise any suitablevoltage, such as, for example, 12V. At 1954, the power assembly 1608energizes a voltage boost convertor 1618. The voltage boost convertor1618 is configured to provide a set voltage. The set voltage comprises avoltage greater than the source voltage provided by the power assembly1608. For example, in some embodiments, the set voltage comprises avoltage of 13V. In a third step 1956, the voltage boost convertor 1618energizes one or more voltage regulators to provide one or moreoperating voltages to one or more circuit components. The operatingvoltages comprise a voltage less than the set voltage provided by thevoltage boost convertor.

In some embodiments, the boost convertor 1618 is coupled to a firstvoltage regulator 1616 configured to provide a first operating voltage.The first operating voltage provided by the first voltage regulator 1616is less than the set voltage provided by the voltage boost convertor.For example, in some embodiments, the first operating voltage comprisesa voltage of 5V. In some embodiments, the boost convertor is coupled toa second voltage regulator 1614. The second voltage regulator 1614 isconfigured to provide a second operating voltage. The second operatingvoltage comprises a voltage less than the set voltage and the firstoperating voltage. For example, in some embodiments, the secondoperating voltage comprises a voltage of 3.3V. In some embodiments, thebattery 1608, voltage boost convertor 1618, first voltage regulator1616, and second voltage regulator 1614 are configured in a daisy chainconfiguration. The battery 1608 provides the source voltage to thevoltage boost convertor 1618. The voltage boost convertor 1618 booststhe source voltage to the set voltage. The voltage boost convertor 1618provides the set voltage to the first voltage regulator 1616. The firstvoltage regulator 1616 generates the first operating voltage andprovides the first operating voltage to the second voltage regulator1614. The second voltage regulator 1614 generates the second operatingvoltage.

In some embodiments, one or more circuit components are energizeddirectly by the voltage boost convertor 1618. For example, in someembodiments, an OLED display 1688 is coupled directly to the voltageboost convertor 1618. The voltage boost convertor 1618 provides the setvoltage to the OLED display 1688, eliminating the need for the OLED tohave a power generator integral therewith. In some embodiments, aprocessor, such as, for example, the safety processor 1604 illustratedin FIGS. 5A and 5B, verifies the voltage provided by the voltage boostconvertor 1618 and/or the one or more voltage regulators 1616, 1614. Thesafety processor 1604 is configured to verify a voltage provided by eachof the voltage boost convertor 1618 and the voltage regulators 1616,1614. In some embodiments, the safety processor 1604 verifies the setvoltage. When the set voltage is equal to or greater than a firstpredetermined value, the safety processor 1604 energizes the firstvoltage regulator 1616. The safety processor 1604 verifies the firstoperational voltage provided by the first voltage regulator 1616. Whenthe first operational voltage is equal to or greater than a secondpredetermined value, the safety processor 1604 energizes the secondvoltage regulator 1614. The safety processor 1604 then verifies thesecond operational voltage. When the second operational voltage is equalto or greater than a third predetermined value, the safety processor1604 energizes each of the remaining circuit components of the segmentedcircuit 1600.

Various aspects of the subject matter described herein relate to methodsof controlling power management of a surgical instrument through asegmented circuit and variable voltage protection. In one embodiment, amethod of controlling power management in a surgical instrumentcomprising a primary processor, a safety processor, and a segmentedcircuit comprising a plurality of circuit segments in signalcommunication with the primary processor, the plurality of circuitsegments comprising a power segment, the method comprising providing, bythe power segment, variable voltage control of each segment. In oneembodiment, the method comprises providing, by the power segmentcomprising a boost converter, power stabilization for at least one ofthe segment voltages. The method also comprises providing, by the boostconverter, power stabilization to the primary processor and the safetyprocessor. The method also comprises providing, by the boost converter,a constant voltage to the primary processor and the safety processorabove a predetermined threshold independent of a power draw of theplurality of circuit segments. The method also comprises detecting, byan over voltage identification and mitigation circuit, a monopolarreturn current in the surgical instrument and interrupting power fromthe power segment when the monopolar return current is detected. Themethod also comprises identifying, by the over voltage identificationand mitigation circuit, ground floatation of the power system.

In another embodiment, the method also comprises energizing, by thepower segment, each of the plurality of circuit segments sequentiallyand error checking each circuit segment prior to energizing a sequentialcircuit segment. The method also comprises energizing the safetyprocessor by a power source coupled to the power segment, performing anerror check, by the safety processor, when the safety processor isenergized, and performing, and energizing, the safety processor, theprimary processor when no errors are detected during the error check.The method also comprises performing an error check, by the primaryprocessor when the primary processor is energized, and wherein when noerrors are detected during the error check, sequentially energizing, bythe primary processor, each of the plurality of circuit segments. Themethod also comprises error checking, by the primary processor, each ofthe plurality of circuit segments.

In another embodiment, the method comprises, energizing, by the boostconvertor the safety processor when a power source is connected to thepower segment, performing, by the safety processor an error check, andenergizing the primary processor, by the safety processor, when noerrors are detected during the error check. The method also comprisesperforming an error check, by the primary process, and sequentiallyenergizing, by the primary processor, each of the plurality of circuitsegments when no errors are detected during the error check. The methodalso comprises error checking, by the primary processor, each of theplurality of circuit segments.

In another embodiment, the method also comprises, providing, by a powersegment, a segment voltage to the primary processor, providing variablevoltage protection of each segment, providing, by a boost converter,power stabilization for at least one of the segment voltages, an overvoltage identification, and a mitigation circuit, energizing, by thepower segment, each of the plurality of circuit segments sequentially,and error checking each circuit segment prior to energizing a sequentialcircuit segment.

Various aspects of the subject matter described herein relate to methodsof controlling an surgical instrument control circuit having a safetyprocessor. In one embodiment, a method of controlling a surgicalinstrument comprising a control circuit comprising a primary processor,a safety processor in signal communication with the primary processor,and a segmented circuit comprising a plurality of circuit segments insignal communication with the primary processor, the method comprisingmonitoring, by the safety processor, one or more parameters of theplurality of circuit segments. The method also comprises verifying, bythe safety processor, the one or more parameters of the plurality ofcircuit segments and verifying the one or more parameters independentlyof one or more control signals generated by the primary processor. Themethod further comprises verifying, by the safety processor, a velocityof a cutting element. The method also comprises monitoring, by a firstsensor, a first property of the surgical instrument, monitoring, by asecond sensor a second property of the surgical instrument, wherein thefirst property and the second property comprise a predeterminedrelationship, and wherein the first sensor and the second sensor are insignal communication with the safety processor. The method alsocomprises preventing, by the safety processor, operation of at least oneof the plurality of circuit segments when the fault is detected, whereina fault comprises the first property and the second property havingvalues inconsistent with the predetermined relationship. The method alsocomprises, monitoring, by a Hall-effect sensor, a cutting memberposition and monitoring, by a motor current sensor, a motor current.

In another embodiment, the method comprises disabling, by the safetyprocessor, at least one of the plurality of circuit segments when amismatch is detected between the verification of the one or moreparameters and the one or more control signals generated by the primaryprocessor. The method also comprises preventing by the safety processor,operation of a motor segment and interrupting power flow to the motorsegment from the power segment. The method also comprises preventing, bythe safety processor, forward operation of a motor segment and when thefault is detected allowing, by the safety processor, reverse operationof the motor segment.

In another embodiment the segmented circuit comprises a motor segmentand a power segment, the method comprising controlling, by the motorsegment, one or more mechanical operations of the surgical instrumentand monitoring, by the safety processor, one or more parameters of theplurality of circuit segments. The method also comprises verifying, bythe safety processor, the one or more parameters of the plurality ofcircuit segments and the independently verifying, by the safetyprocessor, the one or more parameters independently of one or morecontrol signals generated by the primary processor.

In another embodiment, the method also comprises independentlyverifying, by the safety processor, the velocity of a cutting element.The method also comprises monitoring, by a first sensor, a firstproperty of the surgical instrument, monitoring, by a second sensor, asecond property of the surgical instrument, wherein the first propertyand the second property comprise a predetermined relationship, andwherein the first sensor and the second sensor are in signalcommunication with the safety processor, wherein a fault comprises thefirst property and the second property having values inconsistent withthe predetermined relationship, and preventing, by the safety processor,the operation of at least one of the plurality of circuit segments whenthe fault is detected by the safety processor. The method also comprisesmonitoring, by a Hall-effect sensor, a cutting member position andmonitoring, by a motor current sensor, a motor current.

In another embodiment, the method comprises disabling, by the safetyprocessor, at least one of the plurality of circuit segments when amismatch is detected between the verification of the one or moreparameters and the one or more control signals generated by the primaryprocessor. The method also comprises preventing, by the safetyprocessor, operation of the motor segment and interrupting power flow tothe motor segment from the power segment. The method also comprisespreventing, by the safety processor, forward operation of the motorsegment and allowing, by the safety processor, reverse operation of themotor segment when the fault is detected.

In another embodiment, the method comprises monitoring, by the safetyprocessor, one or more parameters of the plurality of circuit segments,verifying, by the safety processor, the one or more parameters of theplurality of circuit segments, verifying, by the safety processor, theone or more parameters independently of one or more control signalsgenerated by the primary processor, and disabling, by the safetyprocessor, at least one of the plurality of circuit segments when amismatch is detected between the verification of the one or moreparameters and the one or more control signals generated by the primaryprocessor. The method also comprises monitoring, by a first sensor, afirst property of the surgical instrument, monitoring, by a secondsensor, a second property of the surgical instrument, wherein the firstproperty and the second property comprise a predetermined relationship,and wherein the first sensor and the second sensor are in signalcommunication with the safety processor, wherein a fault comprises thefirst property and the second property having values inconsistent withthe predetermined relationship, and wherein when the fault is detected,preventing, by the safety processor, operation of at least one of theplurality of circuit segments. The method also comprises preventing, bythe safety processor, operation of a motor segment by interrupting powerflow to the motor segment from the power segment when a fault isdetected prevent.

Various aspects of the subject matter described herein relate to methodsof controlling power management of a surgical instrument through sleepoptions of segmented circuit and wake up control, the surgicalinstrument comprising a control circuit comprising a primary processor,a safety processor in signal communication with the primary processor,and a segmented circuit comprising a plurality of circuit segments insignal communication with the primary processor, the plurality ofcircuit segments comprising a power segment, the method comprisingtransitioning, by the safety processor, the primary processor and atleast one of the plurality of circuit segments from an active mode to asleep mode and from the sleep mode to the active mode. The method alsocomprises tracking, by a timer, a time from a last user initiated eventand wherein when the time from the last user initiated event exceeds apredetermined threshold, transitioning, by the safety processor, theprimary processor and at least one of the plurality of circuit segmentsto the sleep mode. The method also comprises detecting, by anacceleration segment comprising an accelerometer, one or more movementsof the surgical instrument. The method also comprises tracking, by thetimer, a time from the last movement detected by the accelerationsegment. The method also comprises maintaining, by the safety processor,the acceleration segment in the active mode when transitioning theplurality of circuit segments to the sleep mode.

In another embodiment, the method also comprises transitioning to thesleep mode in a plurality of stages. The method also comprisestransitioning the segmented circuit to a first stage after a firstpredetermined period and dimming a backlight of the display segment,transitioning the segmented circuit to a second stage after a secondpredetermined period and turning the backlight off, transitioning thesegmented circuit to a third stage after a third predetermined periodand reducing a polling rate of the accelerometer, and transitioning thesegmented circuit to a fourth stage after a fourth predetermined periodand turning a display off and transitioning the surgical instrument tothe sleep mode.

In another embodiment comprising detecting, by a touch sensor, usercontact with a surgical instrument and transitioning, by the safetyprocessor, the primary processor and a plurality of circuit segmentsfrom a sleep mode to an active mode when the touch sensor detects a userin contact with surgical instrument. The method also comprisesmonitoring, by the safety processor, at least one handle control andtransitioning, by the safety processor, the primary processor and theplurality of circuit segments from the sleep mode to the active modewhen the at least one handle control is actuated.

In another embodiment, the method comprises transitioning, by the safetyprocessor, the surgical device to the active mode when the accelerometerdetects movement of the surgical instrument above a predeterminedthreshold. The method also comprises monitoring, by the safetyprocessor, the accelerometer for movement in at least a first directionand a second direction and transitioning, by the safety processor, thesurgical instrument from the sleep mode to the operational mode whenmovement above a predetermined threshold is detected in at least thefirst direction and the second direction. The method also comprisesmonitoring, by the safety processor, the accelerometer for oscillatingmovement above the predetermined threshold in the first direction, thesecond direction, and a third direction, and transitioning, by thesafety processor, the surgical instrument from the sleep mode to theoperational mode when oscillating movement is detected above thepredetermined threshold in the first direction, second direction, andthird direction. The method also comprises increasing the predeterminedas the time from the previous movement increases.

In another embodiment, the method comprises transitioning, by the safetyprocessor, the primary processor and at least one of the plurality ofcircuit segments from an active mode to a sleep mode and from the sleepmode to the active mode when a time from the last user initiated eventexceeds a predetermined threshold, tracking, by a timer, a time from thelast movement detected by the acceleration segment, and transitioning,by the safety processor, the surgical device to the active mode when theacceleration segment detects movement of the surgical instrument above apredetermined threshold.

In another embodiment, a method of controlling a surgical instrumentcomprises tracking a time from a last user initiated event anddisabling, by the safety processor, a backlight of a display when thetime from the last user initiated event exceeds a predeterminedthreshold. The method also comprises flashing, by the safety processor,the backlight of the display to indicate to a user to look at thedisplay.

Various aspects of the subject matter described herein relate to methodsof verifying the sterilization of a surgical instrument through asterilization verification circuit, the surgical instrument comprising acontrol circuit comprising a primary processor, a safety processor insignal communication with the primary processor and a segmented circuitcomprising a plurality of circuit segments in signal communication withthe primary processor, the plurality of circuit segments comprising astorage verification segment, the method comprising indicating when asurgical instrument has been properly stored and sterilized. The methodalso comprises detecting, by at least one sensor, one or more improperstorage or sterilization parameters. The method also comprises sensing,by a drop protection sensor, when the instrument has been dropped andpreventing, by the safety processor, operation of at least one of theplurality of circuit segments when the drop protection sensor detectsthat the surgical instrument has been dropped. The method also comprisespreventing, by the safety processor, operation of at least one of theplurality of circuit segments when a temperature above a predeterminedthreshold is detected by a temperature sensor. The method also comprisespreventing, by the safety processor, operation of at least one of theplurality of circuit segments when the temperature sensor detects atemperature above a predetermined threshold.

In another embodiment, the method comprises controlling, by the safetyprocessor, operation of at least one of the plurality of circuitsegments when a moisture detection sensor detects moisture. The methodalso comprises detecting, by a moisture detection sensor, an autoclavecycle and preventing, by the safety processor, operation of the surgicalinstrument unless the autoclave cycle has been detected. The method alsocomprises preventing, by the safety processor, operation of the at leastone of the plurality of circuit segments when moisture is detectedduring a staged circuit start-up.

In another embodiment, the method comprises indicating, by the pluralityof circuit segments comprising a sterilization verification segment,when a surgical instrument has been properly sterilized. The method alsocomprises detecting, by at least one sensor of the sterilizationverification segment, sterilization of the surgical instrument. Themethod also comprises indicating, by a storage verification segment,when a surgical instrument has been properly stored. The method alsocomprises detecting, by at least one sensor of the storage verificationsegment, improper storage of the surgical instrument.

The entire disclosures of:

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U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT HAVINGSEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which issued on Feb. 21,2006;

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In accordance with various embodiments, the surgical instrumentsdescribed herein may comprise one or more processors (e.g.,microprocessor, microcontroller) coupled to various sensors. Inaddition, to the processor(s), a storage (having operating logic) andcommunication interface, are coupled to each other.

As described earlier, the sensors may be configured to detect andcollect data associated with the surgical device. The processorprocesses the sensor data received from the sensor(s).

The processor may be configured to execute the operating logic. Theprocessor may be any one of a number of single or multi-core processorsknown in the art. The storage may comprise volatile and non-volatilestorage media configured to store persistent and temporal (working) copyof the operating logic.

In various embodiments, the operating logic may be configured to processthe collected biometric associated with motion data of the user, asdescribed above. In various embodiments, the operating logic may beconfigured to perform the initial processing, and transmit the data tothe computer hosting the application to determine and generateinstructions. For these embodiments, the operating logic may be furtherconfigured to receive information from and provide feedback to a hostingcomputer. In alternate embodiments, the operating logic may beconfigured to assume a larger role in receiving information anddetermining the feedback. In either case, whether determined on its ownor responsive to instructions from a hosting computer, the operatinglogic may be further configured to control and provide feedback to theuser.

In various embodiments, the operating logic may be implemented ininstructions supported by the instruction set architecture (ISA) of theprocessor, or in higher level languages and compiled into the supportedISA. The operating logic may comprise one or more logic units ormodules. The operating logic may be implemented in an object orientedmanner. The operating logic may be configured to be executed in amulti-tasking and/or multi-thread manner. In other embodiments, theoperating logic may be implemented in hardware such as a gate array.

In various embodiments, the communication interface may be configured tofacilitate communication between a peripheral device and the computingsystem. The communication may include transmission of the collectedbiometric data associated with position, posture, and/or movement dataof the user's body part(s) to a hosting computer, and transmission ofdata associated with the tactile feedback from the host computer to theperipheral device. In various embodiments, the communication interfacemay be a wired or a wireless communication interface. An example of awired communication interface may include, but is not limited to, aUniversal Serial Bus (USB) interface. An example of a wirelesscommunication interface may include, but is not limited to, a Bluetoothinterface.

For various embodiments, the processor may be packaged together with theoperating logic. In various embodiments, the processor may be packagedtogether with the operating logic to form a System in Package (SiP). Invarious embodiments, the processor may be integrated on the same diewith the operating logic. In various embodiments, the processor may bepackaged together with the operating logic to form a System on Chip(SoC).

Various embodiments may be described herein in the general context ofcomputer executable instructions, such as software, program modules,and/or engines being executed by a processor. Generally, software,program modules, and/or engines include any software element arranged toperform particular operations or implement particular abstract datatypes. Software, program modules, and/or engines can include routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, program modules, and/or enginescomponents and techniques may be stored on and/or transmitted acrosssome form of computer-readable media. In this regard, computer-readablemedia can be any available medium or media useable to store informationand accessible by a computing device. Some embodiments also may bepracticed in distributed computing environments where operations areperformed by one or more remote processing devices that are linkedthrough a communications network. In a distributed computingenvironment, software, program modules, and/or engines may be located inboth local and remote computer storage media including memory storagedevices. A memory such as a random access memory (RAM) or other dynamicstorage device may be employed for storing information and instructionsto be executed by the processor. The memory also may be used for storingtemporary variables or other intermediate information during executionof instructions to be executed by the processor.

Although some embodiments may be illustrated and described as comprisingfunctional components, software, engines, and/or modules performingvarious operations, it can be appreciated that such components ormodules may be implemented by one or more hardware components, softwarecomponents, and/or combination thereof. The functional components,software, engines, and/or modules may be implemented, for example, bylogic (e.g., instructions, data, and/or code) to be executed by a logicdevice (e.g., processor). Such logic may be stored internally orexternally to a logic device on one or more types of computer-readablestorage media. In other embodiments, the functional components such assoftware, engines, and/or modules may be implemented by hardwareelements that may include processors, microprocessors, circuits, circuitelements (e.g., transistors, resistors, capacitors, inductors, and soforth), integrated circuits, application specific integrated circuits(ASIC), programmable logic devices (PLD), digital signal processors(DSP), field programmable gate array (FPGA), logic gates, registers,semiconductor device, chips, microchips, chip sets, and so forth.

Examples of software, engines, and/or modules may include softwarecomponents, programs, applications, computer programs, applicationprograms, system programs, machine programs, operating system software,middleware, firmware, software modules, routines, subroutines,functions, methods, procedures, software interfaces, application programinterfaces (API), instruction sets, computing code, computer code, codesegments, computer code segments, words, values, symbols, or anycombination thereof. Determining whether an embodiment is implementedusing hardware elements and/or software elements may vary in accordancewith any number of factors, such as desired computational rate, powerlevels, heat tolerances, processing cycle budget, input data rates,output data rates, memory resources, data bus speeds and other design orperformance constraints.

One or more of the modules described herein may comprise one or moreembedded applications implemented as firmware, software, hardware, orany combination thereof. One or more of the modules described herein maycomprise various executable modules such as software, programs, data,drivers, application program interfaces (APIs), and so forth. Thefirmware may be stored in a memory of the controller 2016 and/or thecontroller 2022 which may comprise a nonvolatile memory (NVM), such asin bit-masked read-only memory (ROM) or flash memory. In variousimplementations, storing the firmware in ROM may preserve flash memory.The nonvolatile memory (NVM) may comprise other types of memoryincluding, for example, programmable ROM (PROM), erasable programmableROM (EPROM), electrically erasable programmable ROM (EEPROM), or batterybacked random-access memory (RAM) such as dynamic RAM (DRAM),Double-Data-Rate DRAM (DDRAM), and/or synchronous DRAM (SDRAM).

In some cases, various embodiments may be implemented as an article ofmanufacture. The article of manufacture may include a computer readablestorage medium arranged to store logic, instructions and/or data forperforming various operations of one or more embodiments. In variousembodiments, for example, the article of manufacture may comprise amagnetic disk, optical disk, flash memory or firmware containingcomputer program instructions suitable for execution by a generalpurpose processor or application specific processor. The embodiments,however, are not limited in this context.

The functions of the various functional elements, logical blocks,modules, and circuits elements described in connection with theembodiments disclosed herein may be implemented in the general contextof computer executable instructions, such as software, control modules,logic, and/or logic modules executed by the processing unit. Generally,software, control modules, logic, and/or logic modules comprise anysoftware element arranged to perform particular operations. Software,control modules, logic, and/or logic modules can comprise routines,programs, objects, components, data structures and the like that performparticular tasks or implement particular abstract data types. Animplementation of the software, control modules, logic, and/or logicmodules and techniques may be stored on and/or transmitted across someform of computer-readable media. In this regard, computer-readable mediacan be any available medium or media useable to store information andaccessible by a computing device. Some embodiments also may be practicedin distributed computing environments where operations are performed byone or more remote processing devices that are linked through acommunications network. In a distributed computing environment,software, control modules, logic, and/or logic modules may be located inboth local and remote computer storage media including memory storagedevices.

Additionally, it is to be appreciated that the embodiments describedherein illustrate example implementations, and that the functionalelements, logical blocks, modules, and circuits elements may beimplemented in various other ways which are consistent with thedescribed embodiments. Furthermore, the operations performed by suchfunctional elements, logical blocks, modules, and circuits elements maybe combined and/or separated for a given implementation and may beperformed by a greater number or fewer number of components or modules.As will be apparent to those of skill in the art upon reading thepresent disclosure, each of the individual embodiments described andillustrated herein has discrete components and features which may bereadily separated from or combined with the features of any of the otherseveral aspects without departing from the scope of the presentdisclosure. Any recited method can be carried out in the order of eventsrecited or in any other order which is logically possible.

It is worthy to note that any reference to “one embodiment” or “anembodiment” means that a particular feature, structure, orcharacteristic described in connection with the embodiment is comprisedin at least one embodiment. The appearances of the phrase “in oneembodiment” or “in one aspect” in the specification are not necessarilyall referring to the same embodiment.

Unless specifically stated otherwise, it may be appreciated that termssuch as “processing,” “computing,” “calculating,” “determining,” or thelike, refer to the action and/or processes of a computer or computingsystem, or similar electronic computing device, such as a generalpurpose processor, a DSP, ASIC, FPGA or other programmable logic device,discrete gate or transistor logic, discrete hardware components, or anycombination thereof designed to perform the functions described hereinthat manipulates and/or transforms data represented as physicalquantities (e.g., electronic) within registers and/or memories intoother data similarly represented as physical quantities within thememories, registers or other such information storage, transmission ordisplay devices.

It is worthy to note that some embodiments may be described using theexpression “coupled” and “connected” along with their derivatives. Theseterms are not intended as synonyms for each other. For example, someembodiments may be described using the terms “connected” and/or“coupled” to indicate that two or more elements are in direct physicalor electrical contact with each other. The term “coupled,” however, alsomay mean that two or more elements are not in direct contact with eachother, but yet still co-operate or interact with each other. Withrespect to software elements, for example, the term “coupled” may referto interfaces, message interfaces, application program interface (API),exchanging messages, and so forth.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

The disclosed embodiments have application in conventional endoscopicand open surgical instrumentation as well as application inrobotic-assisted surgery.

Embodiments of the devices disclosed herein can be designed to bedisposed of after a single use, or they can be designed to be usedmultiple times. Embodiments may, in either or both cases, bereconditioned for reuse after at least one use. Reconditioning mayinclude any combination of the steps of disassembly of the device,followed by cleaning or replacement of particular pieces, and subsequentreassembly. In particular, embodiments of the device may bedisassembled, and any number of the particular pieces or parts of thedevice may be selectively replaced or removed in any combination. Uponcleaning and/or replacement of particular parts, embodiments of thedevice may be reassembled for subsequent use either at a reconditioningfacility, or by a surgical team immediately prior to a surgicalprocedure. Those skilled in the art will appreciate that reconditioningof a device may utilize a variety of techniques for disassembly,cleaning/replacement, and reassembly. Use of such techniques, and theresulting reconditioned device, are all within the scope of the presentapplication.

By way of example only, embodiments described herein may be processedbefore surgery. First, a new or used instrument may be obtained and whennecessary cleaned. The instrument may then be sterilized. In onesterilization technique, the instrument is placed in a closed and sealedcontainer, such as a plastic or TYVEK bag. The container and instrumentmay then be placed in a field of radiation that can penetrate thecontainer, such as gamma radiation, x-rays, or high-energy electrons.The radiation may kill bacteria on the instrument and in the container.The sterilized instrument may then be stored in the sterile container.The sealed container may keep the instrument sterile until it is openedin a medical facility. A device may also be sterilized using any othertechnique known in the art, including but not limited to beta or gammaradiation, ethylene oxide, or steam.

One skilled in the art will recognize that the herein describedcomponents (e.g., operations), devices, objects, and the discussionaccompanying them are used as examples for the sake of conceptualclarity and that various configuration modifications are contemplated.Consequently, as used herein, the specific exemplars set forth and theaccompanying discussion are intended to be representative of their moregeneral classes. In general, use of any specific exemplar is intended tobe representative of its class, and the non-inclusion of specificcomponents (e.g., operations), devices, and objects should not be takenlimiting.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art can translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations are not expressly set forth herein for sakeof clarity.

The herein described subject matter sometimes illustrates differentcomponents contained within, or connected with, different othercomponents. It is to be understood that such depicted architectures aremerely examples and that in fact many other architectures may beimplemented which achieve the same functionality. In a conceptual sense,any arrangement of components to achieve the same functionality iseffectively “associated” such that the desired functionality isachieved. Hence, any two components herein combined to achieve aparticular functionality can be seen as “associated with” each othersuch that the desired functionality is achieved, irrespective ofarchitectures or intermedial components. Likewise, any two components soassociated can also be viewed as being “operably connected,” or“operably coupled,” to each other to achieve the desired functionality,and any two components capable of being so associated can also be viewedas being “operably couplable,” to each other to achieve the desiredfunctionality. Specific examples of operably couplable include but arenot limited to physically mateable and/or physically interactingcomponents, and/or wirelessly interactable, and/or wirelesslyinteracting components, and/or logically interacting, and/or logicallyinteractable components.

Some aspects may be described using the expression “coupled” and“connected” along with their derivatives. It should be understood thatthese terms are not intended as synonyms for each other. For example,some aspects may be described using the term “connected” to indicatethat two or more elements are in direct physical or electrical contactwith each other. In another example, some aspects may be described usingthe term “coupled” to indicate that two or more elements are in directphysical or electrical contact. The term “coupled,” however, also maymean that two or more elements are not in direct contact with eachother, but yet still co-operate or interact with each other.

In some instances, one or more components may be referred to herein as“configured to,” “configurable to,” “operable/operative to,”“adapted/adaptable,” “able to,” “conformable/conformed to,” etc. Thoseskilled in the art will recognize that “configured to” can generallyencompass active-state components and/or inactive-state componentsand/or standby-state components, unless context requires otherwise.

While particular aspects of the present subject matter described hereinhave been shown and described, it will be apparent to those skilled inthe art that, based upon the teachings herein, changes and modificationsmay be made without departing from the subject matter described hereinand its broader aspects and, therefore, the appended claims are toencompass within their scope all such changes and modifications as arewithin the true scope of the subject matter described herein. It will beunderstood by those within the art that, in general, terms used herein,and especially in the appended claims (e.g., bodies of the appendedclaims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.). It will be further understood by those within the art that when aspecific number of an introduced claim recitation is intended, such anintent will be explicitly recited in the claim, and in the absence ofsuch recitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to claims containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations.

In addition, even when a specific number of an introduced claimrecitation is explicitly recited, those skilled in the art willrecognize that such recitation should typically be interpreted to meanat least the recited number (e.g., the bare recitation of “tworecitations,” without other modifiers, typically means at least tworecitations, or two or more recitations). Furthermore, in thoseinstances where a convention analogous to “at least one of A, B, and C,etc.” is used, in general such a construction is intended in the senseone having skill in the art would understand the convention (e.g., “asystem having at least one of A, B, and C” would include but not belimited to systems that have A alone, B alone, C alone, A and Btogether, A and C together, B and C together, and/or A, B, and Ctogether, etc.). In those instances where a convention analogous to “atleast one of A, B, or C, etc.” is used, in general such a constructionis intended in the sense one having skill in the art would understandthe convention (e.g., “a system having at least one of A, B, or C” wouldinclude but not be limited to systems that have A alone, B alone, Calone, A and B together, A and C together, B and C together, and/or A,B, and C together, etc.). It will be further understood by those withinthe art that typically a disjunctive word and/or phrase presenting twoor more alternative terms, whether in the description, claims, ordrawings, should be understood to contemplate the possibilities ofincluding one of the terms, either of the terms, or both terms unlesscontext dictates otherwise. For example, the phrase “A or B” will betypically understood to include the possibilities of “A” or “B” or “Aand B.”

With respect to the appended claims, those skilled in the art willappreciate that recited operations therein may generally be performed inany order. Also, although various operational flows are presented in asequence(s), it should be understood that the various operations may beperformed in other orders than those which are illustrated, or may beperformed concurrently. Examples of such alternate orderings may includeoverlapping, interleaved, interrupted, reordered, incremental,preparatory, supplemental, simultaneous, reverse, or other variantorderings, unless context dictates otherwise. Furthermore, terms like“responsive to,” “related to,” or other past-tense adjectives aregenerally not intended to exclude such variants, unless context dictatesotherwise.

In summary, numerous benefits have been described which result fromemploying the concepts described herein. The foregoing description ofthe one or more embodiments has been presented for purposes ofillustration and description. It is not intended to be exhaustive orlimiting to the precise form disclosed. Modifications or variations arepossible in light of the above teachings. The one or more embodimentswere chosen and described in order to illustrate principles andpractical application to thereby enable one of ordinary skill in the artto utilize the various embodiments and with various modifications as aresuited to the particular use contemplated. It is intended that theclaims submitted herewith define the overall scope.

What is claimed is:
 1. A method for controlling a surgical instrument,the method comprising: connecting a power assembly to a control circuit,wherein the power assembly is configured to provide a source voltage;energizing, by the power assembly, a voltage boost convertor circuitconfigured to provide a set voltage greater than the source voltage; andenergizing, by the voltage boost convertor, one or more voltageconvertors configured to provide one or more operating voltages to oneor more circuit components.
 2. The method of claim 1, comprisingenergizing, by the voltage boost convertor, a first regulator configuredto provide a first operating voltage to a first subset of the one ormore circuit components.
 3. The method of claim 2, comprisingenergizing, by the first regulator convertor, a second regulatorconfigured to provide a second operating voltage to a second subset ofthe one or more circuit components.
 4. The method of claim 3, whereinthe voltage boost convertor, the first regulator, and the secondregulator are coupled in a daisy chain configuration.
 5. The method ofclaim 4, comprising providing, by the power assembly, a voltage of about12 volts, the set voltage comprises a voltage of about 13 volts, thefirst operating voltage comprises a voltage of about 5 volts, and thesecond operating voltage comprises a voltage of about 3.3 volts.
 6. Themethod of claim 1, comprising energizing, by the voltage boostconvertor, an organic light emitting diode.
 7. The method of claim 1,comprising verifying, by a processor, the set voltage by comparing theset voltage to a predetermined threshold voltage.
 8. The method of claim7, comprising generating, by an independent voltage regulator, aconstant voltage, wherein the constant voltage is provided to theprocessor.
 9. The method of claim 8, comprising producing, by theindependent voltage regulator, a voltage of 3.3V.
 10. A surgicalinstrument control circuit, comprising: a power assembly configured toprovide a source voltage; a voltage boost convertor coupled to the powerassembly, the voltage boost convertor configured to provide a setvoltage greater than the source voltage; and a first voltage regulatorcoupled to the voltage boost convertor, wherein the first voltageregulator is configured to provide a first operation voltage, whereinthe first operational voltage is less than the set voltage.
 11. Thecontrol circuit of claim 10, comprising a second voltage regulatorcoupled to the first voltage regulator, wherein the second voltageregulator is configured to provide a second operational voltage, whereinthe second operational voltage is less than the first operationalvoltage, and wherein the voltage boost convertor, the first voltageregulator, and the second voltage regulator are coupled in a daisy chainconfiguration.
 12. The control circuit of claim 11, wherein the powerassembly is configured to provide a voltage of about 12 volts, the setvoltage comprises a voltage of about 13 volts, the first operatingvoltage comprises a voltage of about 5 volts, and the second operatingvoltage comprises a voltage of about 3.3 volts.
 13. The control circuitof claim 11, wherein the first voltage regulator is coupled to a firstplurality of circuit components and the second voltage regulator iscoupled to a second plurality of circuit components.
 14. The controlcircuit of claim 11, comprising an independent voltage regulatorconfigured to generate a constant voltage for one or more criticalcircuit components.
 15. The control circuit of claim 14, wherein one ormore critical circuit components comprise a safety processor.
 16. Thecontrol circuit of claim 14, wherein the independent voltage regulatoris configured to produce a voltage of 3.3V.
 17. A method for controllinga surgical instrument, the method comprising: connecting a powerassembly to a control circuit, wherein the power assembly is configuredto provide a source voltage; energizing, by the power assembly, avoltage boost convertor circuit configured to provide a set voltagegreater than the source voltage; and energizing, by the voltage boostconvertor, a safety processor.
 18. The method of claim 17, comprisingenergizing, by the safety processor, a first voltage regulatorconfigured to provide a first operating voltage to a first set ofcircuit components.
 19. The method of claim 18, comprising energizing,by the safety processor, a second voltage regulator configured toprovide a second operating voltage to a second set of circuitcomponents.
 20. The method of claim 19, wherein the power assembly isconfigured to provide a voltage of about 12 volts, the set voltagecomprises a voltage of about 13 volts, the first operating voltagecomprises a voltage of about 5 volts, and the second operating voltagecomprises a voltage of about 3.3 volts.